Note: Descriptions are shown in the official language in which they were submitted.
WO 2022/224219 PCT/1B2022/053788
1
POLYAMIDE COMPOSITION
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S.
Provisional Patent
Application Serial No. 63/178,259 filed April 22, 2021, the disclosure of
which is incorporated
herein in its entirety by reference.
FIELD
[0002] The present disclosure relates to thermoplastic resin
compositions with improved
impact strength, tensile strength, and/or ductility, such as under conditions
that are below 0 C.
BACKGROUND
[0003] Thermoplastic condensation polyamide resins that are
molded or extruded suffer
from insufficient properties for various end uses such as automotive,
electronics, chemical
processing, and heat transfer applications. Various thermoplastic condensation
polyamide resins
that are molded or extruded have insufficient impact strength (or toughness)
and ductility,
especially at temperatures below 0 C, where most commercially available
polyamide resins
appear to fail.
SUMMARY OF THE INVENTION
[0004] The present disclosure provides a composition including a
condensation
polyamide, or a reacted product of the composition, wherein when the
composition or reacted
product is formed into an impact test bar and tested at -30 C according to
ISO 179/2-1eA to
form a -30 C notched impact fractured surface, the composition or reacted
product has: an Sdr
measurement of >10% as obtained from a surface profilometry analysis of the -
30 C notched
impact fractured surface, wherein Sar represents the degree to which the
actual surface area
increases in comparison to a flat state; or a stress whitening zone thickness
of >500 microns at a
halfway distance through the fracture and in a transversal surface cut plane
(TcuT), the
transversal cut plane being perpendicular to the original fracture surface; or
a porosity area
fraction (%) within the first 50 microns below the -30 C notched impact
fractured surface in a
transverse cross-section direction taken at >3 to <5 mm linear distance from
the notch is >5% to
<31%; or a numerical mean of the aspect ratio (pore major axis/minor axis) of
a representative
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sample of pores measured within the first 50 microns below the -30 C notched
impact fractured
surface and along a longitudinal cross-section taken at >3 to <5 mm linear
distance from the
notch of >1.8 to <3.1 and a porosity area fraction measured in the same
location as the numerical
mean of the aspect ratio of at least 5%; or a combination thereof.
[0005] The present disclosure provides a composition including a
condensation
polyamide, or a reacted product of the composition, wherein when the
composition or reacted
product is formed into an impact test bar and tested at -30 C according to
ISO 179/2-1eA to
form a -30 C notched impact fractured surface, the composition or reacted
product has: a
porosity area fraction (%) within the first 50 microns below the -30 C
notched impact fractured
surface in a transverse cross-section direction taken at >3 to <5 mm linear
distance from the
notch of >5% to <31%, and a porosity area fraction (%) at a depth of about 100
microns below
the -30 C notched impact fractured surface in a transverse cross-section
direction taken at >3 to
<5 mm linear distance from the notch of >2 /0 to <17%.
[0006] The present disclosure provides a composition including a
condensation
polyamide, or a reacted product of the composition, wherein when the
composition or reacted
product thereof is formed into a tensile test bar according to ISO 527 and
fractured at room
temperature in accordance with ISO 527, it exhibits an internal microstructure
having >4%
porosity area fraction and an aspect ratio (pore major axis/minor axis) at a
halfway point between
the fracture surface and the grip sections and at the start of the grip
sections of > 1.6 to < 3Ø
[0007] The present disclosure provides a composition including a
condensation
polyamide and a maleated polyolefin, or a reacted product of the composition,
the condensation
polyamide including nylon 66, wherein the amine end group (AEG) index of the
nylon 66 is >65
and <130, wherein an unpolished microtome-cut pellet formed from the
composition or reacted
product thereof subjected to toluene etching at 90 C for 2 hours has a
surface that, as compared
using a magnification of 3000x to 5000x, is less pitted than an identical
composition or reacted
product thereof wherein the amine end group (AEG) index of the nylon 66 is
<65.
[0008] The composition can include the condensation polyamide,
wherein the
condensation polyamide is at least 30 wt% of the composition, wherein the
condensation
polyamide is the predominant polyamide in the composition. The composition can
also include
from >10 wt% to <50 wt% of maleated polyolefin, wherein the maleated
polyolefin includes
maleic anhydride grafted onto a polyolefin backbone, the maleated polyolefin
having a grafted
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maleic anhydride incorporation of >0.05 to <1.5 wt% based on total weight of
the maleated
polyolefin.
[0009] The composition can include the condensation polyamide,
wherein the
condensation polyamide is at least 40 wt% of the composition, wherein the
condensation
polyamide is the predominant polyamide in the composition, wherein the
condensation
polyamide is nylon 66 having an AEG of >65 milliequivalents per kg (meq/kg)
and <130
meq/kg. The composition can also include from >15 wt% to <45 wt% of maleated
polyolefin,
wherein the maleated polyolefin includes maleic anhydride grafted onto a
polyolefin backbone,
the maleated polyolefin having a grafted maleic anhydride incorporation of
>0.05 to <1.5 wt%
based on total weight of the maleated polyolefin.
[0010] The present disclosure provides an article formed from
the composition or the
reacted product thereof. The article can be an extruded or molded article.
[0011] The present disclosure provides a method of making the
composition, the reacted
product thereof, or a combination thereof. The method includes combining the
condensation
polyamide and the maleated polyolefin to form the composition, the reacted
product, or a
combination thereof.
[0012] The present disclosure provides a method of extrusion of
a polyamide resin. The
method includes providing the composition, the reacted product thereof, or the
combination
thereof, to a feed zone of an extr uder. The method includes maintaining
extruder barrel
conditions sufficiently to obtain a polyamide resin melt inside the extruder.
The method includes
producing extrudate from the extruder while optionally recovering vapor from
the extruder via a
vacuum draw.
[0013] In general, industrially available polyamides such as
nylon 66 are not known to
have the adequate sub-zero impact resistance or ductility. An industrial need
continues to exist
for thermoplastic resins, particularly, in the field of polyamides, with
superior impact resistance,
toughness and ductility. Most applications require improved impact resistance
and ductility at
temperatures below 0 C, where most commercially available polyamide resins
appear to fail.
The formulations according to the present disclosure can provide improved
impact resistance,
tensile strength, solvent resistance, and/or ductility, such as at
temperatures below 0 C.
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BRIEF DESCRIPTION OF THE FIGURES
[0014] The drawings illustrate generally, by way of example, but
not by way of
limitation, various aspects of the present invention.
[0015] FIGS. 1A-B illustrate SEM images of various Example 1
specimens according to
the present disclosure.
[0016] FIGS. 2A-F illustrate SEM images of various Example 1 and
2 specimens
according to the present disclosure.
[0017] FIGS. 3A-D illustrate 3-dimensional surface profilometry
of various Example 1
and 2 specimens according to the present disclosure.
[0018] FIG. 4A is a diagram illustrating the orientations of
longitudinal and transverse
cuts from impact tested bars for various test specimens according to the
present disclosure.
[0019] FIG. 4B illustrate photographs of various Example I and 2
specimens according
to the present disclosure.
[0020] FIG. 5 illustrate SEM images showing microporosity
characteristics of the
Example 1E specimen according to the present disclosure.
[0021] FIG. 6 illustrates SEM images of various Example 1 and 2
impact tested
specimens in the transverse orientation according to the present disclosure.
[0022] FIG. 7 illustrate SEM images of the Example 1E impact
tested specimen in the
longitudinal orientation at various lengths from the test notch according to
the present disclosure.
[0023] FIG. 8 illustrates a plot of -30 "V impact strength
(kJ/m2) versus room-
temperature tensile modulus (GPa) data according to the present disclosure.
[0024] FIG. 9A illustrates sample locations analyzed in tensile
tests performed in various
Examples of the present disclosure.
[0025] FIG. 9B illustrates SEM images of various fractured
tensile bars formed from
Example 1 and 2 samples according to the present disclosure.
[0026] FIG. 10 illustrates SEM images of various Example 1
impact tested specimens in
the transverse orientation according to the present disclosure.
[0027] FIG. 11 illustrate SEM images of various Example 1 impact
tested specimens in
the longitudinal orientation according to the present disclosure.
[0028] FIG. 12 illustrates SEM images of various Example 1
tensile tested specimens
according to the present disclosure.
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DETAILED DESCRIPTION OF THE INVENTION
[0029] Reference will now be made in detail to certain aspects
of the disclosed subject
matter. While the disclosed subject matter will be described in conjunction
with the enumerated
claims, it will be understood that the exemplified subject matter is not
intended to limit the
claims to the disclosed subject matter.
[0030] Throughout this document, values expressed in a range
format should be
interpreted in a flexible manner to include not only the numerical values
explicitly recited as the
limits of the range, but also to include all the individual numerical values
or sub-ranges
encompassed within that range as if each numerical value and sub-range is
explicitly recited. For
example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" should be
interpreted to
include not just about O. I% to about 5%, but also the individual values
(e.g., 1%, 2%, 3%, and
4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within
the indicated
range. The statement -about X to Y" has the same meaning as -about X to about
Y," unless
indicated otherwise. Likewise, the statement "about X, Y, or about Z" has the
same meaning as
"about X, about Y, or about Z," unless indicated otherwise.
[0031] In this document, the terms "a," "an," or "the" are used
to include one or more
than one unless the context clearly dictates otherwise. The term "or" is used
to refer to a
nonexclusive "or" unless otherwise indicated. The statement "at least one of A
and B" or "at
least one of A or B" has the same meaning as "A, B, or A and B." In addition,
it is to be
understood that the phraseology or terminology employed herein, and not
otherwise defined, is
for the purpose of description only and not of limitation. Any use of section
headings is intended
to aid reading of the document and is not to be interpreted as limiting;
information that is
relevant to a section heading may occur within or outside of that particular
section.
[0032] In the methods described herein, the acts can be carried
out in any order without
departing from the principles of the invention, except when a temporal or
operational sequence is
explicitly recited. Furthermore, specified acts can be carried out
concurrently unless explicit
claim language recites that they be carried out separately. For example, a
claimed act of doing X
and a claimed act of doing Y can be conducted simultaneously within a single
operation, and the
resulting process will fall within the literal scope of the claimed process.
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[0033] The term "about- as used herein can allow for a degree of
variability in a value or
range, for example, within 10%, within 5%, or within 1% of a stated value or
of a stated limit of
a range, and includes the exact stated value or range.
[0034] The term "substantially" as used herein refers to a
majority of, or mostly, as in at
least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%,
99.99%, or
at least about 99.999% or more, or 100%. The term "substantially free of' as
used herein can
mean having none or having a trivial amount of, such that the amount of
material present does
not affect the material properties of the composition including the material,
such that about 0
wt% to about 5 wt% of the composition is the material, or about 0 wt% to about
1 wt%, or about
wt% or less, or less than, equal to, or greater than about 4.5 wt%, 4, 3.5, 3,
2.5, 2, 1.5, 1, 0.9,
0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt% or less, or
about 0 wt%.
[0035] As used herein, the term "polymer" refers to a molecule
having at least one
repeating unit and can include copolymers.
[0036] The term -conduit" or "conduit structure", as used
herein, may refer to a hollow
channel or duct suitable for conveying a fluid or passage for laying down and
enclosing thin
electrical wires and cables. The conduit cross-section may have a single hole
or multiple holes
depending on the application requirement.
[0037] The term "pipe", as used herein, may embody either right-
cylindrical geometry,
i.e., having circular cross-sectional shape, and other cross-sectional shapes
which may be
elongated in one axis perpendicular to the conduit long axis, for example,
obround and oval
cross-sectional shapes_
[0038] As used herein, -sheet" or -extruded planer sheet" refers
to a broad and
substantially flat or planer section of desired dimension. In some aspects,
the sheet width can be
in the range of 6-inch to 10-ft and the sheet thickness range may be 0.3-5 mm.
[0039] The term "PA6", "N6" or "nylon 6", as used herein, refers
to a polymer
synthesized by polycondensation of caprolactam. The polymer is also known as
polyamide 6,
PA6, or poly(caprolactam).
[0040] The term "N66" or "nylon 66", as used herein, refers to a
polymer synthesized by
polycondensation of hexamethylenediamine (111WD) and adipic acid. The polymer
is also known
as polyamide 66 (or PA66), nylon 6,6, nylon 6-6, nylon 6/6 or nylon-6,6.
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[0041] The term "N12- or "nylon 12", as used herein, refers to a
polymer synthesized by
polycondensation of w-aminolauric acid or ring-opening polymerization of
laurolactam. The
polymer is also known as polyamide 12 (or PA12), nylon 12, poly(laurolactam),
poly(dodecano-
12-lactam), or poly(12-aminododecanoic acid lactam).
[0042] The term "N612" or "nylon 612", as used herein, refers to
a polymer synthesized
by polycondensation of hexamethylenediamine (HMD) and am-dodecanedioic acid
(or C12
diacid). The polymer is also known as polyamide 612 (or PA612), PA 6/12, or
nylon 6/12.
[0043] The term "nylon 66/6T", as used herein, refers to a co-
polymer obtained from
N66 and a polymer of N6-terephthalic acid (TPA).
[0044] The term "nylon 66/61", as used herein, refer to a co-
polymer obtained from N66
and a polymer of N6-isoplithalic acid (IPA).
[0045] As used herein, "PA610" or "nylon-6,10" is a semi-
crystalline polyamide
prepared from hexamethylenediamine (C6 diamine, abbreviated as TIMD) and
decanedioic acid
(Cio diacid). It is commercially available from Arkema, BASF, and such.
[0046] As used herein, "PA66/DI" or "nylon-66/DI" or "PA66/MPMD-
I" refers to a type
of co-polyamide of polyhexamethyleneadipamide (nylon-6,6 or N66 or PA66) and
"DI" which is
a combination of 2-methyl-pentamethylenediamine (or "MPMD") and isophthalic
acid. MPMD
is commercially available as INVISTA Dytelj A amine and industrially known as
"D" in the
abbreviated formulation labeling. Isoplithalic acid is commercially available
and industrially
known as "I" in the abbreviated formulation labeling.
[0047] In some aspects, PA66/DI may contain about 80-99% PA66
and about 1-20% DI
on the mass basis, for example, about (on wt:wt basis) 99:1 or 97:3 or 95:5 or
92:8 or 90:10 or
85:15 or 80:20 for PA66:DI achieved for the salts on dry basis. The "DI" part
in PA66/DI is
about 50:50 (molar) or about 40:60 D:I (mass ratio). The RV range for PA66/DI
can be between
35 and 60 and may contain amine end groups (AEG) between 40 to 80 meg/kg, for
example,
between 60 to 80 meg/kg, or 65 meg/kg, or 70 meg/kg. Standard batch
evaporation and batch
autoclave polymerization processes are used to produce the copolymer. These
methods are
polymerization processes generally known to the skilled person.
[0048] INVISTA Dytek's' A amine is commercially produced by
hydrogenating 2-
methylglutaronitrile (or "MGN"). MGN is a branched C6 dinitrile obtained as a
side-product
from butadiene double-hydrocyanation process of adiponitrile [or `ADN1
manufacture. The
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otherwise disposed MGN side-product can be recycled and reused in the
production of INVISTA
Dytek A amine or the "D" portion; the PA66/DI produced by this process,
therefore, is
considered to have the recycled amine content coming from the "D" portion.
[0049] As used herein, "High-AEG polyamide 66" or "High AEG N66"
is commercially
available from INVISTA. High-AEG polyamide 66 is characterized by its RV range
of 30-80,
for example 35-75 RV, for example, 35-70 RV, and AEG of >65 milliequivalents
per kg
(meq/kg) and <130 meq/kg of the polyamide resin, for example >75 meq/kg and
<125 meq/kg,
>80 meq/kg and <125 meq/kg, >90 meq/kg and <120 meq/kg of the polyamide resin.
[0050] As used herein, "PA610" or "nylon-6,10" is a semi-
crystalline polyamide
prepared from hexamethylenediamine (C6 diamine, abbreviated as EIMD) and
decanedioic acid
(Cio diacid). It is commercially available from Arkema, BASF, and such.
[0051] As used herein, "PA612" is commercially available from
DuPont, EMS,
Shakespeare, Nexis. PA612 is a semi-crystalline polyamide prepared from
hexamethylenediamine (C6 diamine, abbreviated as HMD) and dodecanedioic acid
(C12 diacid,
abbreviated as DDDA).
[0052] As used herein, FUSABONDTM N216" (previously known as
"Amplify
GR216") is a maleic anhydride grafted polyolefin and is commercially available
from Dow
Chemical.
[0053] As used herein, "ZeMacTm E60" is a chain extender that is
a copolymer of maleic
anhydride and ethylene and is commercially available from Vertellus.
[0054] As used herein, "Zytel FE7108" is commercially available
from DuPont,
AmeriChem.
[0055] As used herein, "Stabaxol P100" is a type of hydrolysis
stabilizer commercially
available from Lanxess.
[0056] As used herein, "room temperature" means ambient
temperature, such as the
ambient temperature under which testing is performed, such as about 23 C
(e.g., about 19 C to
about 27 C).
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Composition including a condensation polyamide and a maleated polyolefin.
[0057] The present invention provides a composition including a
condensation
polyamide, or a reacted product of the composition. When the composition or
reacted product is
formed into an impact test bar and tested at -30 C according to ISO 179/2-leA
to form a -30 C
notched impact fractured surface, the composition or reacted product can have:
an Sdr
measurement of >10% as obtained from a surface profilometry analysis of the -
30 C notched
impact fractured surface, wherein Sr represents the degree to which the actual
surface area
increases in comparison to a flat state; or a stress whitening zone thickness
of >500 microns at a
halfway distance through the fracture and in a transversal surface cut plane
(Tcur), the
transversal cut plane being perpendicular to the original fracture surface; or
a porosity area
fraction (%) measured within the first 50 microns below the -30 'V notched
impact fractured
surface in a transverse cross-section direction taken at >3 to <5 mm linear
distance from the
notch can be >5% to <31%; or a numerical mean of the aspect ratio (pore major
axis/minor axis)
of a representative sample of pores measured within the first 50 microns below
the -30 C
notched impact fractured surface and along a longitudinal cross-section taken
at >3 to <5 mm
linear distance from the notch can be >1.8 to <3.1 and a porosity area
fraction measured in the
same location as the numerical mean of the aspect ratio can be at least 5%; or
a combination
thereof.
[0058] When the composition or reacted product is formed into an
impact test bar and
tested at -30 C according to ISO 179/2-leA to form a -30 C notched impact
fractured surface,
the composition or reacted product can have an Sdr measurement of >10% as
obtained from a
surface profilometry analysis of the -30 C notched impact fractured surface,
wherein Sdr
represents the degree to which the actual surface area increases in comparison
to a flat state. For
example, the Sdr can be 10% to 30%, or 10% to 20%, or 10% to 15%, or less than
or equal to
30% but greater than or equal to 10%, 10.5, 11, 11.5, 12, 12.5, 13, 13.5,
14,14.5, 15, 15.5, 16,
16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22,22.5, 23, 23.5, 24,
24.5, 25, 25.5, 26,
26.5, 27, 27.5, 28, 28.5, 29, or 29.5%.
[0059] When the composition or reacted product is formed into an
impact test bar and
tested at -30 C according to ISO 179/2-leA to form a -30 C notched impact
fractured surface,
the composition or reacted product can have a stress whitening zone thickness
of >500 microns
at a halfway distance through the fracture and in a transversal surface cut
plane (Tcur), the
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transversal cut plane being perpendicular to the original fracture surface.
For example, the stress
whitening zone thickness can be 500 microns to 800 microns at a halfway
distance through the
fracture and in the TCUT plane, or 550 microns to 700 microns, or less than or
equal to 800
microns but greater than or equal to 500, 510, 520, 530, 540, 550, 560, 570,
580, 590, 600, 620,
640, 660, 680, 700, 720, 740, 760, or 780 microns.
[0060]
When the composition or reacted product is formed into an impact test bar
and
tested at -30 C according to ISO 179/2-leA to form a -30 C notched impact
fractured surface,
the composition or reacted product can have a porosity area fraction (%)
measured within the
first 50 microns below the -30 C notched impact fractured surface in a
transverse cross-section
direction taken at >3 to <5 mm linear distance from the notch of >5% to <31%.
For example, the
porosity area fraction can be >5% to <31%, or >8% to <27%, or >12% to <23%, or
equal to or
less than 31% but greater than or equal to 4%, 5, 6, 7, 8, 9, 10, II, 12, 13,
14, IS, 16, 17, 18, 19,
20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30%.
[0061]
When the composition or reacted product is formed into an impact test bar
and
tested at -30 C according to ISO 179/2-leA to form a -30 C notched impact
fractured surface,
the composition or reacted product can have a numerical mean of the aspect
ratio (pore major
axis/minor axis) of a representative sample of pores measured within the first
50 microns below
the -30 C notched impact fractured surface and along a longitudinal cross-
section taken at >3 to
<5 111111 linear distance from the notch can be >1.8 to <3.1. The numerical
mean of the aspect
ratio can be >1.8 to <3.1 and a porosity area fraction measured in the same
location as the
numerical mean of the aspect ratio can be at least 5%. For example, the
numerical mean of the
aspect ratio can be >1.8 to <3.1, >2.0 to <3.0, >2.1 to <2.8, or less than or
equal to 3.1 but greater
than or equal to 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or
3Ø
[0062]
When the composition or reacted product is formed into an impact test bar
and
tested at -30 C according to ISO 179/2-1eA to form a -30 C notched impact
fractured surface,
the composition or reacted product can have a porosity area fraction (%) at a
depth of about 100
microns below the -30 C notched impact fractured surface in a transverse
cross-section direction
taken at >3 to <5 mm linear distance from the notch of >2% to <17%. For
example, the porosity
area fraction can be >2% to <17%, >3% to <14%, >4% to <12%, or less than or
equal to 17% but
greater than or equal to 2%, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14,15, or
16%.
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[0063] The present invention provides a composition including a
condensation
polyamide, or a reacted product of the composition. When the composition or
reacted product is
formed into an impact test bar and tested at -30 C according to ISO 179/2-1eA
to form a -30 C
notched impact fractured surface, the composition or reacted product can have
a porosity area
fraction (%) within the first 50 microns below the -30 C notched impact
fractured surface in a
transverse cross-section direction taken at >3 to <5 mm linear distance from
the notch of >5% to
<31% (e.g., >5% to <31%, or >8% to <27%, or >12% to <23%, or equal to or less
than 31% but
greater than or equal to 4%, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24,
25, 26, 27, 28, 29, or 30%), and a porosity area fraction (%) at a depth of
about 100 microns
below the -30 C notched impact fractured surface in a transverse cross-
section direction taken at
>3 to <5 min linear distance from the notch of >2% to <17% (e.g., >2% to <17%,
>3% to <14%,
>4% to <12%, or less than or equal to 17% but greater than or equal to 2%, 3,
4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, or 16%). When the composition or reacted product thereof
is formed into a
tensile test bar according to ISO 527 and fractured at room temperature in
accordance with ISO
527, it exhibits an internal microstructure having >4% porosity area fraction
(e.g., e.g., >5% to
<31%, or >8% to <27%, or >12% to <23%, or equal to or less than 31% but
greater than or equal
to 4%, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23,
24, 25, 26, 27, 28, 29, or
30%) and an aspect ratio (pore major axis/minor axis) at a halfway point
between the fracture
surface and the grip sections and at the start of the grip sections of >1.6 to
<3.0 (e.g., >1.6 to
<3.0, >1.7 to <2.8, >1.8 to <2.5, or less than or equal to 3 but greater than
or equal to 1.6, 1.7,
1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7,2.8, or 2.9).
[0064] The present invention provides a composition including a
condensation
polyamide and a maleated polyolefin, or a reacted product of the composition.
When the
composition or reacted product is formed into an impact test bar and tested at
-30 C according
to ISO 179/2-1eA to form a -30 C notched impact fractured surface, the
composition or reacted
product can have increased cavitation upon impact fracture as compared to an
identical
composition or reacted product thereof (e.g., comparative composition or
reacted product
thereof) that is free of the maleated polyolefin and/or wherein the nylon 66
of the comparative
composition or reacted product thereof has an amine end group (AEG) index of
<65.
[0065] The present invention provides a composition including a
condensation
polyamide and a maleated polyolefin, or a reacted product of the composition.
The condensation
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polyamide can include nylon 66 having an amine end group (AEG) index of is >65
and <130.
An unpolished microtome-cut pellet formed from the composition or reacted
product thereof
subjected to toluene etching at 90 C for 2 hours can have a surface that, as
compared using a
magnification of 3000x to 5000x (e.g., using a scanning electron microscope),
is less pitted than
an identical composition or reacted product thereof wherein the amine end
group (AEG) index of
the nylon 66 is <65. The AEG index of the nylon 66 in the composition or
reacted product
thereof can be any suitable AEG, such as >65 and <130 (i.e., >65 meq/kg and
<130 meq/kg), or
>80 and <125, >80 and <120, or less than or equal to 130 but greater than or
equal to 60, 65, 70,
75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, or 130.
[0066]
When the composition or reacted product is formed into an impact test bar
and
tested at -30 C according to ISO 179/2- 1 eA to form a -30 C notched impact
fractured surface,
the composition or reacted product can have an Sdr measurement of > I 0% as
obtained from a
surface profilometry analysis of the -30 C notched impact fractured surface,
wherein Sdr
represents the degree to which the actual surface area increases in comparison
to a flat state,
wherein a -30 C impact strength (kJ/m2) of the composition or reacted product
can be at least
40% higher at an identical tensile modulus (GPa) as compared to a composition
including a
condensation polyamide or reaction product thereof that does not have an Sdr
measurement of
>10% as obtained from a surface profilometry analysis of a -30 C notched
impact fractured
surface thereof.
[0067]
The composition or reacted product thereof of the present invention can
include
the condensation polyamide. The condensation polyamide can be at least 30 wt%
of the
composition. The condensation polyamide can be the predominant polyamide in
the
composition. The composition or reacted product thereof can include from >10
wt% to <50 wt%
of maleated polyolefin, such as >15 wt% to <50 wt%, >15 wt% to <45 wt%, >20
wt% to <50
wt%, >20 wt% to <45 wt%, >20.5 wt% to <50 wt%, >21 wt% to <50 wt%, >21.5 wt%
to <50
wt%, >22 wt% to <50 wt%, >22.5 wt% to <50 wt%, or less than or equal to 50 wt%
but greater
than or equal to 10 wt%, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23,
24, 25, 26, 27, 28, 29,
30, 35, 40, 41, 42, 43, 44, 45, 46, 47, 48, or 49%. The maleated polyolefin
can include maleic
anhydride grafted onto a polyolefin backbone. The maleated polyolefin can have
a grafted
maleic anhydride incorporation of >0.05 to <1.5 wt% based on total weight of
the maleated
polyolefin.
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[0068] The condensation polyamide can be one or more polyamides
that can be formed
via condensation (e.g., via reaction of an amine and carboxylic acid group to
form an amide and
release water). The condensation polyamide can include any suitable one or
more condensation
polyamides. The condensation polyamide can include nylon 66, nylon 66/6T,
nylon 66/61, nylon
66/DI, or a combination thereof. The condensation polyamide can be nylon 66.
The
condensation polyamide can be nylon 66/DI. The condensation polyamide can be
substantially
free of polyamides (prior to being combined into the composition and combining
with any other
polyamides therein) other than one or more of nylon 66, nylon 66/6T, nylon
66/61, and nylon
66/DI. The condensation polyamide can be nylon 66, and the condensation
polymer (prior to
being combined into the composition) can be substantially free of polyamides
other than nylon
66. The condensation polyamide can be nylon 66/DI, and the condensation
polyamide (prior to
being combined into the composition) can be substantially free of polyamides
other than nylon
66/DI. The condensation polyamide can be the predominant polyamide in the
composition, such
that the condensation polyamide has a higher concentration in the composition
than any other
polyamide in the composition. The condensation polyamide can have any suitable
relative
viscosity (RV), such as determined via a 8.4 wt% solution in 90 wt% formic
acid method (e.g.,
ASTNI D789), such as equal to or greater than 35, 40, or 45, or such as equal
to or less than 100,
90, or 80, or such as less than or equal to 100 but equal to or greater than
35, 36, 37, 38, 39, 40,
41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95,
or such as 30-80, 35-
75, or 42-50, or such as 35-100, 40-90, or 45-80. The condensation polyamide
can form any
suitable proportion of the composition, such as at least 30 wt%, 40, or at
least 50 wt%, or 30-
99.9 wt%, 60-99.9 wt%, or >40 to <50 wt%, or less than or equal to 99.9 wt%
but greater than or
equal to 30 wt%, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 82, 84, 86, 88, 90,
92, 94, 95, 96, 97, 98,
99, or 99.5 wt%.
[0069] The nylon 66/6T can include 0.1 mol% to 99.9 mol% PA66,
or 50 mol% to 99
mol%, or 80 mol% to 99 mol% PA66, or greater than or equal to 0.1 mol%, 0.5,
1, 2, 4, 8, 10,
15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 90, 92, 94, 96, 98, or
99 mol% PA66. The
"6T" portion can include a mole ratio of "6" to "T" of equal to or greater
than 1:100, 5:95, 10:90,
20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20, 90:10, 95:5, or 100:1. The
nylon 66/DI can
include 0.1 mol% to 99.9 mol% PA66, or 50 mol% to 99 mol%, or 80 mol% to 99
mol% PA66,
of less than 100:1 but greater than or equal to 0.1 mol%, 0.5, 1, 2, 4, 8, 10,
15, 20, 25, 30, 35, 40,
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45, 50, 55, 60, 65, 70, 75, 80, 90, 92, 94, 96, 98, or 99 mol% PA66. The "DI-
portion can
include a mole ratio of "D" to "I" of less than 100:1 but greater than or
equal to 1:100, 5:95,
10:90, 20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20, 90:10, 95:5, or 100:1.
The nylon 66/61
can include 0.1 mol% to 99.9 mol /0PA66, or 50 mol% to 99 mol%, or 80 mol% to
99 mol%
PA66, of less than 100:1 but greater than or equal to 0.1 mol%, 0.5, 1, 2, 4,
8, 10, 15, 20, 25, 30,
35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 90, 92, 94, 96, 98, or 99 mol% PA66.
The "6I" portion can
include a mole ratio of "6" to "I" of less than 100:1 but greater than or
equal to 1:100, 5:95,
10:90, 20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20, 90:10, 95:5, or 100:1.
[0070] In various aspects, the composition can be free of
additional polyamides beyond
what is included in the condensation polyamide. In other aspects, the
composition further
includes an additional polyamide, in addition to the condensation polyamide,
the additional
polyamide including nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon
66/6T, nylon
66/61, nylon 66/DI, nylon 66/1)6, nylon 66/DT, nylon 66/610, nylon 66/612,
nylon 11, nylon 46,
nylon 69, nylon 1010, nylon 1212, nylon 6T/DT, nylon DT/DI, a polyamide
copolymer, or a
combination thereof. The additional polyamide can form any suitable proportion
of the
composition, such as >0 to <85 wt%, or less than or equal to 85 wt% but
greater than or equal to
0.1 wt%, 0.5, 1, 2,4, 6, 8, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65,
70, or 75 wt%. The
additional polyamide can be nylon 6. The composition can be free of nylon 6
(e.g., the
composition can have a concentration of nylon 6 of 0 wt% to <1 wt%). The
additional
polyamide can be a nylon-6,6/1V1P1VID-I copolymer.
[0071] The composition can optionally further include
polycaproamide (N6),
polyhexamethylene decanamide (N610), polyhexamethylene dodecanamide (N612),
polyhexamethylene succinamide (N46), polyhexamethylene azelamide (N69),
polydecamethylene sebacamide (N1010), polydodecamethylene dodecanamide
(N1212), nylon
11 (N11), polylaurolactam (N12), nylon 6T/DT, nylon DT/DI, syndiotactic
polystyrene (SPS),
styrene-maleic anhydride (SMA), imidized styrene-maleic anhydride (SMI), or
combinations
thereof. The level of one or more of these additional components can be up to
50% by weight of
the total composition, such as less than or equal to 50 wt% but greater than
or equal to 0.1 wt%,
0.5, 1,2, 4, 6, 8, 10, 15, 20, 25, 30, 35, 40, or 45 wt%.
[0072] In various aspects, the condensation polyamide is chosen
from nylon 66, nylon
66/6T, nylon 66/61, and a combination thereof, and the composition further
includes a nylon-
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6,6/MPMD-I copolymer. The condensation polyamide can be nylon 66, and the
composition can
further include a nylon-6,6/MPMD-I copolymer. The condensation polyamide can
be 30 wt% to
60 wt% of the composition, or less than or equal to 60 wt% but greater than or
equal to 30 wt%,
35, 40, 45, 50, or 55 wt%. The nylon-6,6/MPIVID-I copolymer can be a random
copolymer. The
nylon-6,6/MPMD-I copolymer can form any suitable proportion of the
composition, such as >2
to <50 wt%, >25 to <35 wt%, >0.2 wt% to < 10 wt%, or less than or equal to 50
wt% but greater
than or equal to 0.2 wt%, 0.4, 0.6, 0.8, 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 16,
18, 20, 22, 24, 26, 28, 30,
32, 34, 36, 38, 40, 42, 44, 46, or 48 wt%.
[0073]
The maleated polyolefin includes a polyolefin or polyacrylate backbone
having
pendant maleic anhydride groups grafted thereto. The polyolefin component can
optionally be
an ionomer. The polyolefin can be any suitable polyolefin polymer or
copolymer. The
polyolefin can include EPDM, ethylene-octene, polyethylene, polypropylene, or
a combination
thereof. In various aspects, the maleated polyolefin is free of EPDM. The
maleated polyolefin
can have any suitable grafted maleic anhydride incorporation, such as a
grafted maleic anhydride
incorporation of less than 10 wt%, or of 0.01 to 10 wt%, based on total weight
of the maleated
polyolefin, such as >0.1 to <1.4 wt%, >0.15 to <1.25 wt%, or less than or
equal to 1.25 wt% but
equal to or greater than 0.1 wt%, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1,
1.1, 1.2, or 1.3 wt%. The
maleated polyolefin can have any suitable glass transition temperature (Tg),
such as >-70 C to
<0 'V, >-60 'V to <-20 'V, >-60
to <-30 C, or less than or equal to 0 C but greater than or
equal to -70 C, -65, -60, -55, -50, -45, -40, -35, -30, -25, -20, -15, -10,
or -5 C. The maleated
polyolefin can form any suitable proportion of the composition, such as >15
wt% to <50 wt%,
>15 wt% to <45 wt%, >20 wt% to <50 wt%, >20 wt% to <45 wt%, >20.5 wt% to <50
wt%, >21
wt% to <50 wt%, >21.5 wt% to <50 wt%, >22 wt% to <50 wt%, >22.5 wt% to <50
wt%, or less
than or equal to 50 wt% but greater than or equal to 10 wt%, 11, 12, 13, 14,
15, 16, 17, 18, 19,
20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 41, 42, 43, 44, 45, 46,
47, 48, or 49%.
[0074] The maleated polyolefin can be any suitable maleic
anhydride-grafted polyolefin.
A variety of maleated polyolefins are commercially available. These may
include, but are not
limited to, AMPLIFYTm GR Functional Polymers or FUSABONIDTM N216, commercially
available from Dow Chemical Co. (AmplifyTM GR 202, AmplifyTM GR 208, AmplifyTM
GR 216,
AmplifyTM GR380), ExxelorTM Polymer Resins commercially available from
ExxonMobil
(ExxelorTm VA 1803, ExxelorTM VA 1840, ExxelorTM VA1202, ExxelorTM PO 1020,
ExxelorTM
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PO 1015), ENGAGETM 8100 Polyolefin Elastomer commercially available from Dow
Elastomer,
Bondyrame 7103 Maleic Anhydride-Modified Polyolefin Elastomer commercially
available
from Ram-On Industries LP, and the like. Table 1 lists non-limiting
commercially available
modified polyolefins.
[0075] Table 1. Commercially available modified polyolefins.
Polyolefin Commercial Manuf.
/ Trade Modification Level
Name (wt%) in
Polyolefin
Polypropylene ExxonMobil /
ExxelorTM VA1840 0.2¨ 0.5
Polypropylene Ram-On
Industries / Bondyram <1
7103
Very low-density Dow Chemicals /
AmplifyTM 0.25 ¨ 0.5
Polyethylene (vLDPE) GR208
Polypropylene ExxonMobil /
ExxelorTM P01015 0.25 ¨ 0.5
Ethylene alpha olefin ExxonMobil / ExxelorTM VA1202 0.5 ¨ 1
Modified ethylene Dow Chemicals / 0.5 ¨ 1
copolymer FUSABONDTM or AmplifyTM
GR216
Pure Ethylene ExxonMobil /
ExxelorTM VA1803 0.5 ¨ 1
Low-density Dow Chemicals /
AmplifyTm > 1
Polyethylene (LDPE) GR202
Maleic anhydride- Mitsui TAFMERTm high- ¨1
modified polyolefin performance elastomer
Very low density OREVAC SK
functional
polyethylene polymer
[0076] In Table 1, the term -Modification Level (wt%) in
Polyolefin" means the
functionalized level in the polyolefin tested. For example, in the first row
of Table 1,
polypropylene with 0.2-0.5 wt% modification level means it is a modified
polyolefin having 0.2-
0.5% grafted maleic anhydride content.
[0077] In various aspects, the composition can include glass
fibers or other glass
reinforcements, or the composition can be substantially free of glass fibers
or other glass
reinforcements. The composition can include >1 wt% to <50 wt% glass fibers or
other
reinforcing fibers, >10 wt% to <42 wt%, >10 wt% to <35 wt%, >15 wt% to <30
wt%, >0 wt% to
<2 wt%, or less than or equal to 50 wt% but equal to or greater than 5 wt%,
10, 15, 20, 25, 30,
35, 40, or 45 wt%.
[0078] In various aspects, the condensation polyamide has an AEG
of >65
milliequivalents per kg (meq/k4) and <130 meq/kg; or the maleated polyolefin,
or domains
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thereof, is/are uniformly distributed in the condensation polyamide or in the
composition; or the
condensation polyamide has an RV of at least 35; or the condensation polyamide
is chosen from
nylon 66, nylon 66/6T, nylon 66/61, nylon 66/DI, and a combination thereof; or
a combination
thereof
100791 The composition including the condensation polyamide and
the maleated
polyolefin, or the reacted product thereof, can be a compounded composition
including one or
more other components. The one or more components other than the condensation
polyamide,
the maleated polyolefin, and reaction products thereof, can be any suitable
one or more other
components, such as including a modified polyphenylene ether, an impact
modifier, a flame
retardant, a lubricant (e.g., CRODAMIDETm), a chain extender, a heat
stabilizer, a colorant
additive, a filler, a conductive fiber, glass fibers, another polyamide other
than the condensation
polyamide, or a combination thereof The one or more other components can
include a chain
extender including a dialcohol, a bis-epoxide, a polymer including epoxide
functional groups, a
polymer including anhydride functional groups, a bis-N-acyl bis-caprolactam, a
diphenyl
carbonate, a bisoxazoline, an oxazolinone, a diisocyanate, an organic
phosphite, a bis-
ketenimine, a dianhydride, a carbodiimide, a polymer including carbodiimide
functionality, or a
combination thereof. Examples of flame retardants can include Exolit OP
1080P, Exolit OP
1314, Exolit OP 1400, and the like. Exole FR additives are commercially
available from
Clariant. Examples of colorants can include commercial products available in
the thermoplastics
industry, such as, Black MB Colorant (e.g., carbon black or Nigrosine black
dye). Examples of
other additives, such as heat stabilizer, chain extenders, cross linkers, may
include copper or
organic-based such as ZeMacTm amorphous copolymers, Irganox B1171, Irganox
B1098,
BruggolenTM TP-H1802, BruggolenTM M1251, and the like. For example, Irganox
B1171 is a
commercial polymer additive product of BASF. The ZeMacTm amorphous copolymers
are
commercially available from VertellusTM (www.vertellus.com).
100801 The one or more other components can include a chain
extender. The chain
extender can be capable of reacting with the amine and/or acid terminal groups
of the
condensation polyamide and/or of the reaction product thereof with the
maleated polyolefin,
thereby connecting two polyamide chains. The chain extender can be any
suitable chain
extender, such as a dialcohol (e.g., ethylene glycol, propanediol, butanediol,
hexanediol, or
hydroquinone bis(hydroxyethyl)ether), a bis-epoxide (e.g., bisphenol A
diglycidyl ether),
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polymers having epoxide functional groups (e.g., as pendant and/or terminal
functional groups),
polymers including anhydride functional groups, bis-N-acyl bis-caprolactams
(e.g., isophthaloyl
bis-caprolactam (IBS), adipoyl bis-caprolactam (ABC), or terephthaloyl bis-
caprolactam (TBC)),
diphenyl carbonates, bisoxazolines, oxazolinones, diisocyanates, organic
phosphites (triphenyl
phosphite, caprolactam phosphite), bis-ketenimines, or dianhydrides. The chain
extender can be
a polymer including anhydride functional groups, such as a maleic anhydride-
polyolefin
copolymer (e.g., an alternating copolymer of maleic anhydride and ethylene).
For end-uses that
require hydrolysis resistance, chain extenders that are known to improve
hydrolysis resistance
are preferred. The chain extender can be any suitable proportion of the
composition or reacted
product thereof, such as >0.05 to <5 wt% or >0.05 to <2 wt%, or less than or
equal to 5 wt% but
greater than or equal to 0.05 wt%, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8,
0.9, 1, 1.1, 1.2, 1.3, 1.4,
1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2,
4.4, 4.6, or 4.8 wt%.
[0081] The composition including the condensation polyamide and
maleated polyolefin,
or the reacted product thereof, can have any suitable melt strength. For
example, the
composition or reacted product thereof can exhibit a melt strength of >0.3 to
<1.0 N in a
Rheotens test conducted at 270 C to 290 C, a moisture level of 0.03-0.1%,
and an extrusion
speed of 300-700 mm/s, or a melt strength of >0.8 to <1.0 N, or a melt
strength of less than or
equal to 1 N and greater than or equal to 0.3, 0.35, 0.4, 0.45, 0.5, 0.55,
0.6, 0.65, 0.7, 0.75, 0.8,
0.85, 0.9, or 0.95 N.
[0082] The maleated polyolefin, domains thereof, or reaction
products thereof with the
condensation polyamide, can have any suitable distribution in the condensation
polyamide (and
in any additional polyamides present) or in the composition. For example, the
maleated
polyolefin, reaction product thereof, or domains thereof, can have a uniform
or homogeneous
distribution in the condensation polyamide (and any additional polyamides
present) or in the
composition. The uniformity or homogeneity can be present on a molecular
level, such that the
molecules of the maleated polyolefin or reaction product thereof are
homogeneously distributed
therein. The maleated polyolefin or reaction product thereof can form domains
within the
condensation polymer (and any other polyamides present) or within the
composition; in some
aspects, the maleated polyolefin or reaction product thereof can be at least
partially immiscible
with the condensation polymer. For example, the condensation polymer (and any
other
polyamides present), or all polymeric components other than the maleated
polyolefin, or the
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remainder of the composition, can form a continuous phase, and the maleated
polyolefin or a
reaction product thereof can form a discontinuous phase (domains) therein,
such that the
maleated polyolefin or reaction product thereof primarily resides in islands
in a condensation
polyamide sea. In various aspects, articles described herein, formed from the
composition that
includes the condensation polyamide and the maleated polyolefin, the reacted
product thereof, or
a combination thereof, can include a uniform or homogeneous distribution of
the maleated
polyolefin, reaction products thereof, and/or domains of the maleated
polyolefin or reaction
products thereof
Reacted product of the composition including a condensation polyamide and a
maleated
polyolefin.
[0083] The present invention provides a reacted product that is
a reaction product of the
composition including the condensation polyamide and the maleated polyolefin.
The reacted
product of the composition can include one or more products formed via
reaction of the
condensation polyamide and the maleated polyolefin, such as a polyamide-
polyolefin copolymer
formed from at least partial reaction of the condensation polyamide and the
maleated polyolefin.
[0084] The reacted product can include the composition including
the condensation
polyamide and the maleated polyolefin wherein any suitable proportion of the
condensation
polyamide has reacted with the maleated polyolefin. For example, the reacted
product can
include the polyamide-polyolefin copolymer in a concentration range of >50 to
<7500 ppmw,
>100 to <4900 ppmw, >225 to <3750 ppmw, or less than or equal to 7500 ppmw but
greater than
or equal to 50, 100, 250, 500, 750, 1,000, 1,500, 2,000, 2,500, 3,000, 3,500,
4,000, 4,500, 5,000,
6,000, 7,000, or 8,000 ppmw. In some aspects, the amount of polyamide-
polyolefin copolymer
can be calculated by multiplying the concentration of the maleated polyolefin
with the
modification level of the maleated polyolefin. For example, for a reacted
product made from
80:20 (wt:wt) polyamide:modified polyolefin having 0.5 wt.% grafted (e.g.:
maleated)
modification, the total reacted polyamide-polyolefin modification
functionality in the sample
(assuming all grafted maleic anhydride reacts, which may not occur) can be
calculated as
(0.20)*(0.005)*10b = 1000 ppmw.
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[0085] Without limiting the scope of the disclosure with a
recitation of a theoretical
mechanism, the generalized chemical reaction schematically represented in
Scheme 1 is one
approach to understand the interaction of a maleated olefin copolymer with a
polyamide.
[0086] Scheme 1. Generalized chemical reaction.
3
.79k
..?=z=
. _______________________________________ .4;" " d
A
[0087] Structure D in Scheme 1 represents the condensation
polyamide. Structure A in
Scheme 1 represents the polyolefin, and Structure C represents the maleated
polyolefin (a maleic
anhydride-grafted polyolefin). The terms "degree of maleation" or
"modification level", as used
interchangeably herein, means the extent of which the olefin copolymer
(structure A) has been
reacted with maleic anhydride (structure B). Structure E represents a reaction
product formed
from reaction of the condensation polyamide and the maleated polyolefin.
Article formed from the composition or the reacted product thereof.
[0088] The present disclosure provides an article formed from
the composition including
the condensation polyamide and the maleated polyolefin, from the reacted
product of the
composition, or a combination thereof. The article can be resistant to cold-
temperature cracking.
The article can be a molded article or an extruded article. The article can
include glass fibers, or
the article can be substantially free of glass fibers and/or other reinforcing
fibers. The article can
be produced using any suitable method, such as using blow molding (pressure
and suction),
extrusion, compression molding, thermoforming, injection molding, or other
industrial processes.
[0089] In various aspects, the article can be a conduit (e.g., a
pipe or tube). The conduit
can be chosen from a conduit that is rigid, flexible, curved, bent,
serpentine, partially corrugated,
fully corrugated, and a combination thereof. The conduit can have any suitable
cross-section,
such as round, oval, oblong, square, rectangle, triangle, star, polygonal, and
a combination
thereof The conduit can be an extruded conduit.
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21
[0090] In various aspects, the article can be an extruded sheet.
The article can be a
folded extruded sheet, or an unfolded extruded sheet. The sheet can be a film.
The sheet can
have any suitable thickness, such as a thickness of 0.01 mm to 10 mm, or 0.1
mm to 10 mm, or
0.2 mm to 6 mm, or less than or equal to 10 mm but greater than or equal to
0.01 mm, 0.02, 0.04,
0.06, 0.08, 0.1, 0.15, 0.2, 0.4, 0.6, 0.8, 1, 1.5,2, 2.5,3, 3.5,4, 4.5, 5,
5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9,
or 9.5 mm. The sheet can have any suitable width-to-thickness ratio, such as
at least 10, or at
least 20, or >10 to <40,000, or >20 to <20,000, or greater than or equal to
10, 20, 40, 60, 80, 100,
150, 200, 250, 500, 750, 1,000, 1,500, 2,000, 2,500, 5,000, 10,000, 15,000,
20,000, 25,000,
30,000, 35,000, or 40,000. The sheet can exhibit an impact resistance (e.g.,
as measured using a
heavy duty impact tester such as BYK-Gardner USA Model 1120 or 5545) in kJ/m2
that is within
10% of an impact resistance of a poly carbonate sheet of like thickness under
like impact
resistance testing conditions, such as within 1%, 2, 3, 4, 5, 6, 7, 8, 9, or
within 10%.
[0091] The article can be any suitable article. For example, the
article can be an
automotive article, a building construction article, a conveyor system
article, an article for use in
the petrochemical industry, an internal or external enclosure for
telecommunication equipment,
or another article for use in an application seeking metal parts replacement,
such as for weight-
shedding without or with minimal performance compromise. The article can
include a film, a
mat, a liner, a flooring, a construction material, a pad, a shutter, a panel,
a belt, a slide, an
enclosure, a vehicle component, an architectural component, or a combination
thereof. The
article can include a slip sheet, a die cutting mat, a silo liner, a die
cutting mat, a truck bed liner,
flooring (e.g., for residential, commercial, and/or transportation end uses),
a construction
material (e.g., roofing shingles, roofing panels, siding shingles, roofing
shingles and
underlayments for any of the foregoing), a ground pad (e.g., pads for rotating
equipment and
structures), a construction envelope system (e.g., residential or commercial
construction
envelope systems), a storm-resistant shutter (e.g., hurricane and tornado
shutters), a hail-resistant
panel, a geo-textile (e.g., pond liner), a conveying system component (e.g., a
belt or slide), an
electronic equipment enclosure, or a combination thereof.
Method of making the composition or the reacted product thereof.
[0092] The present disclosure provides a method of making the
composition including
the condensation polyamide and the maleated polyolefin, of making the reacted
product of the
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composition, or a combination thereof. The method includes combining the
condensation
polyamide and the maleated polyolefin to form the composition, the reacted
product thereof, or a
combination thereof.
[0093] In various aspects, the method can include combining the
condensation polyamide
and the maleated polyolefin (e.g., and allowing the two to at least partially
react to form a reacted
product of the composition) before adding a chain extender thereto. In other
aspects, the method
of making the composition including the condensation polyamide and the
maleated polyolefin or
the reacted product thereof, includes combining the condensation polyamide,
the maleated
polyolein, and the chain extender at once without allowing any extra time for
the condensation
polyamide and the maleated polyolefin to react. In other aspects, the
composition including the
condensation polyamide and the inaleated polyolefin, or the reacted product
thereof, is
substantially free of chain extender.
[0094] The method can include providing to a first compounder
extruder zone a feed
including the condensation polyamide and the maleated polyolefin. The method
can include
maintaining the first compounder extruder zone conditions sufficient to obtain
a first
compounded polyamide melt inside the first compounder extruder zone. The
method can include
introducing a chain extender to the first compounded polyamide melt in a
second compounder
extruder zone. The method can also include maintaining the second compounder
extruder zone
conditions sufficient to obtain a second compounded polyamide melt inside the
second
compounder extruder zone, wherein the second compounded polyamide melt is the
composition
including the condensation polyamide and the maleated polyolefin or the
combination thereof.
The second compounder extruder zone is downstream of the first compounder
extruder zone and
can be any suitable distance from the first compounder extruder zone; the
chain extender can be
added at any suitable location along the length of the screw extruder barrel.
The temperature of
the compounded polyamide melts can be any suitable temperature, such as 240 to
320 C, 240 to
300 C, 240 to 265 C, or less than or equal to 320 C and greater than or
equal to 240 C, 250,
260, 270, 280, 290, 300, or 310 C.
[0095] The first compounder extruder zone can be substantially
free of the chain
extender, and/or of any chain extender. The chain extender can be >0.05 to <5
wt% of the
second compounded polyamide melt. The method can further include producing an
article from
the second compounded polyamide melt; for example, the method can include
producing
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extrudate from the second compounded polyamide melt or producing a molded
article from the
second compounded polyamide melt.
[0096] An extruder used to make the composition including the
condensation polyamide
and the maleated polyolefin or the reacted product thereof, can be a screw
extruder (e.g., a single
screw extruder, a vented twin-screw extruder, or an unvented twin-screw
extruder). A barrel of
the screw extruder can include the first compounder extruder zone and the
second compounder
extruder zone. Providing the feed to the first compounder extrusion zone can
include providing
the feed to a feed inlet of the barrel. The screw extruder can have a suitable
diameter, such as a
diameter of 10-30 mm, such as 18-26 mm, such as 10 mm, 11, 12, 13, 14, 15, 16,
17, 18, 19, 20,
22, 24, 26, 28, or 30 mm. The LID ratio of the extruder can be any suitable
ratio, such as 30-70,
or 40-56.
[0097] In various aspects, the chain extender can be introduced
to the second
compounder extruder zone in the barrel a suitable distance away from the feed
inlet. For
example, the chain extender can be introduced to the second compounder
extruder zone at least
1/4 of the length of the barrel from the feed inlet of the barrel. The chain
extender can be
introduced to the second compounder extruder zone at least 1/2 of the length
of the barrel from
the feed inlet of the barrel. The chain extender can be introduced to the
second compounder
extruder zone at least 3/4 of the length of the barrel from the feed inlet of
the barrel. The chain
extender can be introduced to the second compounder extruder zone sufficiently
far from an
outlet of the barrel to provide mixing of the chain extender with the first
compounded polyamide
melt to form the second compounded polyamide melt, and equal to or greater
than 1/4 of the
length of the barrel from the feed inlet of the barrel, or 1/2, 3/4, or more.
The chain extender can
be introduced to the second compounder extruder zone sufficiently far from an
outlet of the
barrel to provide mixing of the chain extender with the first compounded
polyamide melt to form
the second compounded polyamide melt, and equal to or greater than 20% of the
length of the
barrel from the feed inlet of the barrel, or 30%, 40, 50, 60, 70, 80, 90, or
95% or more of the
length of the barrel from the feed inlet of the barrel.
[0098] In various aspects, the introducing of the chain extender
to the first compounded
polyamide melt in the second compounder extruder zone can include introducing
the chain
extender to the first compounded polyamide melt after a certain weight
percentage of the
maleated polyolefin has incorporated into the condensation polyamide or into
the composition.
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Incorporation into the condensation polyamide or into the composition can
include homogeneous
blending of the chain extender with the condensation polyamide or the
composition (e.g., on a
molecular level, or of domains of the maleated polyolefin or a reaction
product thereof),
formation of a reaction product of the maleated polyolefin (e.g., with the
condensation
polyamide), formation of domains of the maleated polyolefin or a reaction
product thereof in the
condensation polyamide or the composition, or a combination thereof. The
introducing of the
chain extender to the first compounded polyamide melt in the second compounder
extruder zone
can include introducing the chain extender to the first compounded polyamide
melt after at least
50 wt% of the maleated polyolefin fed has incorporated into the condensation
polyamide, or
greater than or equal to 50%, 60%, 70%, 80%, 90%, greater than or equal to
95%, or after about
100% of the maleated poly olefin has incorporated into the condensation
polyamide.
[0099] The present disclosure provides a method of extrusion of
a polyamide resin. The
method can include providing the composition including the condensation
polyamide and the
maleated polyolefin, the reacted product thereof, or a combination thereof, to
a feed zone of an
extruder. The method can include maintaining extruder barrel conditions
sufficiently to obtain a
polyamide resin melt inside the extruder. The method can also include
producing extrudate from
the extruder while optionally recovering vapor from the extruder via a vacuum
draw.
[0100] Without undue experimentation but with such references as
"Extrusion, The
Definitive Processing Guide and Handbook", "Handbook of Molded Part Shrinkage
and
Warpage"; "Specialized Molding Techniques"; "Rotational Molding Technology";
and
"Handbook of Mold, Tool and Die Repair Welding", all published by Plastics
Design Library
(elsevier.corn website), the skilled person can make suitable articles of any
conceivable shape
and appearance using the composition and/or reacted composition of the present
disclosure, such
as from the second compounded polyamide melt.
Industrial Utility.
[0101] The industrial applicability of the disclosed polyamide
resin compositions and
reacted products thereof can be realized in the processes of making articles
by blow molding
(pressure or suction), extrusion, compression molding, thermoforming,
injection molding, and
other such industrial processes. The improved impact resistance and ductility
of these polyamide
resins, especially at the sub-zero operating conditions, can make these resins
suitable for
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automotive, building construction, conveyer systems, petrochemicals, internal
and external
enclosures for telecommunications equipment, and many other applications
seeking metal parts
replacement for weight-shedding without the performance compromise. Articles
made from the
disclosed polyamide compositions will find applications in a variety of
industries for their light-
weight, durability, and improved impact resistance/ductility properties, such
as improved impact
toughness properties measured at temperatures below 0 C (cold impact
resistance).
Examples
[0102] Various aspects of the present invention can be better
understood by reference to
the following Examples which are offered by way of illustration. The present
invention is not
limited to the Examples given herein.
General procedure for producing compounded material.
[0103] A twin-screw vented extruder having a co-rotating screw
with an L/D ratio of 50
is used for compounding. The unit has one main feeder and at least three side
feeders. A feed
rate of 1 kg/hr is used. The twin-screw co-rotating/turning is set to 1000 RPM
to provide high
shear for effective compounding. The total compounder throughput is 15 kg/hr.
[0104] The compounding unit has at least three vent ports: one
atmospheric port and two
vacuum ports. A knock-out pot was provided in this operation. The rotating
twin screws impart
forward momentum to the heated mass inside the barrel. The barrel is heated
along its length to
melt the polymer_ The temperature was 280 C for the nylon 66 Examples.
[0105] The processing section of the twin-screw compounder is
set up to suit various
process needs and to allow a wide variety of processes, such as compounding
processes.
Polymer, fillers, and additives (as described below) are continuously fed into
the first barrel
section of the twin screw using a metering feeder. The products are conveyed
along the screw
and are melted and mixed by kneading elements in the plastification section of
the barrel. The
polymer then travels along to a side port where fillers (if used, as described
below), such as glass
fiber. The polymer then travels on to degassing zones and from there to a
pressure build zone
where it then exits the die via an at least 3-mm hole as a lace. The cast lace
is fed into a water
bath to cool and to enable it to be cut into chips via a pelletizer. The unit
is able to withstand at
least 70 bar die pressure. A die with four holes, each of 3 mm diameter, is
used for pelletizing.
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[0106] The compounded, cylindrical extruded pellet having a
diameter of 3 mm and a
length of 4 mm is produced using the above equipment. The moisture content of
the pelletized
material is <0.2 wt.%.
Materials used in examples.
[0107] Feedstock PA66 polyamide, as used herein, is a
commercially available INVISTA
nylon 66 (or N66) grade under the Tradename INVISTATm U4500 or U4800 polyamide
resin.
The PA66 has standard RV range of 80 to 240, for example, 42-50.
[0108] The PA66/DI used in the Examples has a relative viscosity
(RV) of 45. In the
Example compositions containing PA66/DI, the recycled amine content is >0.2
wt.% and < 10
wt.% of the total composition, wherein the DI content is 8 wt.% of the total
composition.
[0109] Other non-limiting co-polyamides suitable for use in
place of the PA66/DI used in
the present examples include 66/D6, 66/DT, 6T/DT, 66/610, 66/612, and such.
Test methods used in the examples
[0110] ASTM D789: Relative viscosity (RV) measurement method.
[0111] ISO 527: Tensile Test conducted at room temperature.
[0112] ISO 179/2-1eA: Notched Charpy Impact Test. Tests were
conducted at -30 C.
[0113] An improvement in melt strength is evidenced by an
increase in the R* value
which is defined as the ratio of the low shear rate viscosity at 1 sec.-1 of
the composition to the
high shear rate viscosity at 100 sec.-I, at a predetermined optimum processing
temperature: R* =
(viscosity at 1 5ec-1)/(viscosity at 100 sec1). The concept of melt viscosity
and R* value is
further discussed in U.S. Pat. No. 5,576,387 (assigned to Sabic Innovative
Plastics) and Abolins
et al. U.S. Pat. No. 4,900,786.
[0114] Another way to determine the melt strength for polymers
is by using Rheotens
test method. In this method, a vertical strand of a polymer melt is drawn at a
constant extension
rate. The draw force (usually measured in centi Newtons (cN), or Newtons (N))
needed to
elongate the strand is measured. Such Rheotens test device is commercially
available from
GOTTFERT (www.goettfert.com) for determining various rheological properties of
plastics and
rubbers, for example, melt strength, melt elasticity, tensile strength
measurements, etc. The melt
strand take away speeds (or extension rates) during the Rheotens measurement
can range
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between 0 to 1200 mm/sec. The polymer melt strength is generally described in
centi Newtons
(cN) as determined using a Rheotens device, for example a Goettfert Rheotens
tester, at
specimen-dependent particular temperature and at certain mm/sec of take away
speed.
101151 Scanning Electron Microscope (SEM) analysis: The SEM
analysis was performed
using a JSM-7200F field emission scanning electron microscope for the samples
prepared in the
Examples. For analysis of etching effects, samples were prepared by
microtoming at room
temperature. The term "microtoming" as used herein means cutting extremely
thin slices of
material, known as sections, for microscopy analysis. The sectioned specimens
were then
immersed in toluene at 90 C for 2 hrs.
[0116] Determination of the sample toughness and tensile
elongation when exposed to
mechanical stress (by fracturing the specimen) was performed to understand
correlations
between energy dissipation in the polymer matrix and the observed
microstructural
characteristics. Crack deflection for the tested samples was qualitatively
determined by
observing the % roughness on fractured surfaces. Cavitation (porosity) effects
were observed by
a quantitative determination of the stress whitening zone thicknesses for
tested samples along
with 2D measurement of porosity area fraction below the fracture surface in
the bulk material.
Shear yielding (deformation) effects manifested in pore elongation were
quantitatively
determined by measuring the aspect ratio (ratio of major to minor axis of a
fitted ellipse) of
porosity.
[0117] The test bar specimens for impact fracture testing were
formed into an impact test
bar and tested at -30 C according to ISO 179/2-1eA to form a -30 C notched
impact fractured
surface.
[0118] For tensile testing at room temperature, test bar
specimens were prepared and
tested according to the ISO 527 test method.
[0119] As used in the Examples, "room temperature" means the
ambient temperature
under which testing was performed, which was generally about 23 C (e.g.,
about 19 C to about
27 'V).
Examples 1(A-K). Compounded Polyamide Specimens
[0120] Table 2 gives compositional ranges for the several
polyamide samples that were
compounded using the general procedure detailed above.
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[0121] Table 2. Polyamide Samples A-K (Ex. IA-1K).
Component A B C D EF GH I JK
(wt. %)
48 RV PA66 (U4800) 73.5 58.5 -
High AEG PA66 (45 RV) (INVISTA
- 73.5 54.55 74 42.3 77 45 45 79 48.1
U4591)
PA66/DI (45 RV) - 30 - 30
29 - 30.9
Maleated poly olefin (DOW
25 25 25 25 25 25 22 22.5 25 20 20
FUSABOND' N216)
PA610 18
PA612 15 -
Black MB Colorant (e.g.: carbon black or
0.6 0.6 0.6 1.0 - 1.0
- 1.5 -
Nigrosine black dye)
Heat stabilizer (e.g., Cu-based or organic
1.2 1.0 1.2 -
based such as Irganox B1171)
Chain extender (e.g., ZeMac TM E60) - 0.25 -
Antioxidant (BASF Irganox0 or
1.0 1.0
1.0 1.0 1.0
Anicrichein)
Hydrolysis stabilizer (e.g., Stabaxol
- 0.5 -
P100)
Zyle1R FE7108 0.9 0.9 0.9
TOTAL 100 100 100 100 100 100 100 100 100 100 100
[0122] The melt strength is determined using a Rheotens test
method. For example, the
melt strength for the compounded polymer resin of the Ex. IE or IF specimens
is measured to be
in the 0.3-1.0 Newton range (typically 0.7 N) at 270-290 C (typically 280 C)
test temperature
for polymer samples having 0.03-0.1 wt% moisture (typically 0.06 wt%) and at
300-700 mm/s
extrusion rate (typically 500 mm/s) or strand take away speed.
101231 FIGS. 1A-B show the SEM visual representation of samples
at 3000x (left-side of
FIGS. 1A-B) and 5000x (right-side of FIGS. IA-B) magnifications. The Ex. IA
specimen is
shown in FIG. 1A and the Ex. lE specimen is shown in FIG. 1B.
[0124] The 2-hour immersion of the pellet microtomes in toluene
at 90 C. was observed
to be effective to show differences in the polymer structure by SEM analysis.
Toluene appeared
to etch out or dissolve out loosely bonded maleated polyolefin portions from
the polymer matrix.
It is evidenced by the pitted (or hollowed out) 1-micron or less
microstructures in FIG. IA for
the Ex. lA specimen, which contained 25 wt.% maleated polyolefin component in
the regular
PA66 matrix.
[0125] The hollowed-out microstructures were not prevalent in
FIG. 1B for the Ex. 1E
specimen that contained about 73.5 wt.% high AEG PA66 and about 25 wt.%
maleated
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polyolefin. FIG. 1B shows lesser signs of maleated polyolefin dissolution in
toluene, possibly
due to more imide linkages. The Ex. lE specimen exhibited significant
"smearing effect" during
microtome as evidenced by the vertically inclined smeared bands visible in
FIG. 1B.
[0126] The SEM images shown in FIG. lA corresponding to the Ex.
IA specimen and
FIG. 1B corresponding to the Ex. 1E specimen were further processed to assess
the surface
porosity that was visible via the toluene etching method at 90 C for 2 hrs.
It was observed that
the toluene-etched surface porosity for the Ex. lE specimen shown in FIG. 1B
was of the order
of less than one-half of that for the Ex. 1A specimen shown in FIG. 1A. Though
not bound by
any theory, this may be indicative of lesser sign of maleated polyolefin
dissolution in toluene
possibly due to more imide linkages in the case of Ex. lE compared to that for
Ex. 1A. A higher
toluene-etched surface porosity for Ex. lA versus that for Ex. lE may indicate
more extraction
of maleated polyolefin from its dissolution in the etching solvent.
Examples 2A-C. Sample Toughness Determination (by fracturing the specimen).
[0127] In addition to three representative polyamide test
specimens of Examples 1A, 1E,
and 1F, three commercially available polyamide samples labeled Samples 2A-C
were analyzed.
The properties of these six test specimens are given in Table 3A below.
[0128] Table 3A. Test Specimens for toughness determination
under fracture conditions.
Sample ID lA 1E 1F 2A 2B
2C
Commercial PA12 Commercial PA612
Commercial High
Material class PA66 PA66 PA66
(Extrusion Grade) (Extrusion Grade)
Tough PA66
Moisture absorption, at
2.1 2.2 2.0 0.6 1.2
2.0
50% RH (%)
Tensile strength, DAM
47 46 45 41 54
50
(MPa)
Elongation Co, break,
122 149 123 163 20
45
Tensile modulus, DAM
1.53 1.47 1.20 0.96 1.97
1.78
(GPa)
23 C Notched charpy
102 107 111 88 43
72
impact, DAM (kJ/m2)
-30 C Notched charpy
47 90 85 87 15
33
impact, DAM (kJ/m2)
RH ¨ Relative Humidity; DAM ¨ Dry as Molded
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Fractured surface roughness by -30 C notched impact test.
[0129] The SEM analysis images in FIGS. 2A-F show differences in
surface roughness
observed for the fractured surfaces from impact bars tested at -30 C. For all
examples shown in
FIG. 2A-F, the surface notch was on the left-side and the fracture path was
from left to right.
[0130] The -30 C notched impact fractured surfaces were further
analyzed using surface
profilometry. The 3-dimensional profile images analyzed for roughness
measurements are
shown in FIGS. 3A-D. The surface profilometry analysis yielded the Table 3B
quantitative data
for the analyzed specimens.
[0131] Table 3B. Surface profilometry analysis.
Sample ID Sa (microns) Sdr (%) FIG.
IA 25.93 8.4 FIG. 3A
lE 21.78 14.0 FIG. 3B
2B 17.82 10.7 FIG. 3C
2C 20.32 6.3 FIG. 3D
[0132] In Table 3A, the term "Sa" was measured in microns and
defined as an arithmetic
mean of the peak heights over the scanned surface. The term "Sdr" was measured
as % and
defined as the degree to which the actual surface area increases in comparison
to the flat state.
For example, an "Sdr" value of 0% means an entirely flat surface.
[0133] The measured "Sdr" values of the -30 C notched impact
fractured surfaces show
the specimen order: 2C < 1A < 2B < 1E.
[0134] The highest "Sdr" value of 14% for the Ex. lE specimen
was indicative of a
rougher fractured surface in comparison to the others analyzed. Generally, and
not bound by any
theory, a rougher fracture surface morphology may be a sign of more impact
energy dissipation
due to crack deflection, increasing the material's ability to withstand a
greater impact force prior
to fracture.
[0135] Representative polyamide test specimens of Examples 1G,
1H, and 11 were
analyzed. The properties of these test specimens are given in Table 3C.
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10136] Table 3C. Test specimens for toughness determination
under fracture conditions.
Sample ID 1G 1H 11
Material class PA66 PA66 PA66
Tensile strength, DAM (MPa) 50 47 48
Elongation @ break, DAM (%) 124 113 137
Tensile modulus, DA_M (GPa) 1.56 1.52 1.41
23 C Notched charpy impact, DAM
101 99 104
(kJ/m2)
-30 C Notched charpy impact, DAM
74 73 96
(kJ/m2)
RH - Relative Humidity; DAM - Dry as Molded
Stress whitening determination.
[0137] Standard impact test specimens were machined per the ISO
179/2-leA test
method. All samples were impact tested at -30 C per ISO 179/2-1eA test
method.
[0138] A schematic of one-half of a fractured impact tested bar
is shown in the left side
of FIG. 4A. The bar was sliced down the middle along the fracture path
starting from the notch
end. This resulted in two halves, one of which is shown as for each Example as
longitudinal or
-LcuT" samples in the photograph of FIG. 4B, with the original impact fracture
running along the
top edge from left (notch) to right. The second half of the fractured impact
bar was cut
perpendicular to the fracture path from the side at the halfway point (4-mm
from start or end of
fracture) to yield a transverse or "Tull' section and is shown on the right
side of FIG. 4A and in
the bottom row of the photograph of FIG. 4B.
[0139] The depth of the stress whitening zone at the mid-point
of the fractured surface as
seen in the -Tom" or transverse cross-section was measured and recorded in
Table 4 for each
sample. A total of three specimens were cut for each sample type with a
minimum of three
measurements taken per specimen. The visually observed stress whitening zones
in the -LcuT"
and "TcuT" specimens are photographically shown in FIG. 4B.
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[0140] Table 4. Stress whitening determination after impact
testing at -30 C.
Test Material Stress Whitening Zone Thickness
Ed, Halfivay Point
through Fracture in TcuT direction
Specimen Class
(values in microns)
lA PA66 323
lE PA66 627
1F PA66 430
2A PA12 483
2B PA612 0
2C PA66 0
[0141] It was observed that the impact test bar stress whitening
zone thickness for the Ex.
lE specimen in the PA66 material class was unexpectedly larger than the other
tested specimens.
Though not bound by any theory, a larger stress whitening zone developed upon
impact may be
an indication of increased impact energy dissipation resulting in superior
fracture toughness.
Porosity and shear yielding characterization of impact tested specimens.
[0142] Fractured bars from ISO 179/2-leA notched Charpy impact
tests conducted at -30
C for Table 2 specimens from above were evaluated for their internal
microstructure including
cavitation (or porosity) and shear yielding characteristics using the SEM and
imaging analysis.
The fracture impact bars were notched along the edge or side and then
fractured at or near liquid
nitrogen temperatures to yield longitudinal (parallel to the original impact
bar fracture path) or
transverse (perpendicular to the original impact bar fracture path) sections
that would preserve
the internal microstructures generated during the original impact bar
fracture. This allowed
detailed microstructural analysis of the areas directly below the original
fracture surface in both
the longitudinal and transverse orientations. Specimens were examined
carefully to ensure a
clean fracture prior to any analysis. The transverse fracture was done at a
point halfway along
the original fracture surface or ¨4 mm from the original Charpy notch.
[0143] As an illustration, the Ex. lE specimen microstructure
porosity characteristics
across the depth below its original fracture surface from SEM analysis are
shown in FIG. 5. This
longitudinal fracture slice was observed at ¨5 mm from the Charpy specimen
notch. Porosity,
which is readily observed in the bulk material directly below the impact
fracture surface was not
observed in the un-tested material. Hence, the porosity observed is a direct
result of the impact
fracture process. The pores immediately below the surface were elongated the
most, an
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indication of a high degree of shear yielding and energy dissipation.
Magnified views at depths
of about 50 um, about 125 um, about 200 um and about 300 um also show
significant amounts
of porosity. The formation of pores (cavitation) and their elongation (shear
yielding), which is
an indication of increased energy dissipation in the bulk material, can be
correlated with the
relatively high impact toughness values observed at -30 C in Table 3A. The
level of porosity
and aspect ratio of pores decreased as a function of depth.
[0144] SEM images of transverse fracture slices taken
perpendicular to the original
Charpy fracture surface at ¨4mm from the notch for Ex. 1A, 1E, 2B, and 2C
specimens
immediately below and 100 um below the surface are shown in FIG. 6. A
significant amount of
porosity is observed for Ex. 1E, which is comparable to that seen in FIG. 5.
Since a transverse
view is shown in FIG. 6, the elongation of pores is not as apparent. In
contrast with the Ex. lE
specimen, the specimens of Examples l A, 2B, and 2C show little to no porosity
directly below
and at a depth of 100 um below the surface as shown in FIG. 6. The large
differences in amount
of porosity and pore elongation can be translated to differences in
cavitation, shear yielding and
energy dissipation. Further, the increased porosity and pore elongation for
Ex. 1E can be
correlated with its significantly higher fracture toughness values at -30 C
reported in Table 3A
relative to Examples 1A, 2B, and 2C.
[0145] Similarly, SEM images of transverse fracture slices taken
perpendicular to the
original Charpy fracture surface at ¨4 nun from the notch for Ex. 1G, 1H and
II, immediately
below and 100 gm below the surface, are shown in FIG. 10. While the Ex. 1G and
1H samples
were impact tested at -30 C, the Ex. 1I sample was tested at -40 C (with an
impact toughness of
77 kJ/m2). SEM images of longitudinal fracture slices taken parallel to the
original Charpy
fracture surface at ¨4 mm from the notch are shown in FIG. 11. The observed
microstructures
were consistent with those for Ex. 1E (as shown in FIGS. 6 and 7). The
relatively large amounts
of porosity and pore elongation can be attributed to cavitation and shear
yielding which results
in energy dissipation. Further, the increased porosity and pore elongation for
1G, 1H and ILI test
samples can be correlated with their significantly higher low temperature
fracture toughness of
>70 kJ/m2 relative to those observed for Examples 1A, 2B, and 2C.
[0146] The importance of porosity (cavitation) and pore
elongation (shear yielding) and
the resulting energy dissipation and direct correlation with -30 C impact
toughness was
demonstrated above. An effort was made to quantify these microstructural
features contributing
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to energy dissipation and improved toughness by measuring the level of
porosity as % area
fraction and pore elongation in terms of its aspect ratio (ratio of major to
minor axis of a fitted
ellipse). These measurements were made on representative SEM images using
ImageJ image
analysis software.
101471 The measured porosity area fractions (%) for the -30 C
impact bar fracture
specimen in the transverse cross-section at a linear distance of ¨4 mm from
Charpy notch using
Impact Test method ISO 179/2-leA are represented in Table 5. Measurements were
taken
immediately below and at a depth of 100 p.m below the surface from SEM images
at 5000x and
10,000x. High magnifications were required because of the relatively small
size of pores. Two
automated built-in algorithms and a manual method of setting the threshold in
ImageJ were used
to obtain porosity area fractions. Routine background smoothing and image
filtering techniques
were also used. The average pore count for each data point in Table 5 was
about 1250.
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[0148] Table 5. Porosity Area Fraction for -30 C Impact Test
fracture specimen of Ex.
1E.
Area Fraction (%)
Surface 100 [im below
12.7 6.2
12.5 6.3
12.7 2.6
17.7 2.9
15.5 2.4
4.9 5.6
21.2 2.5
24.2 3.7
18.1 5.1
9.5 3.9
13.3 11.6
18.1 11.6
19.1 17.3
22.0 8.8
22.2 9.0
22.8 13.7
30.8 12.1
9.1
10.4
Average 17.5 7.6
Std dev 6.3 4.4
Min 4.9 2.4
Max 30.8 17.3
[0149] Porosity area fraction measurements similarly made using
ImageJ analysis on the
Ex. 1G, 1H, and 11 samples, as shown in FIG. 10, were found to be consistent
with those shown
for the Ex. 1E sample in Table 5.
[0150] The measured porosity aspect ratios for the -30 C impact
bar fracture specimen
(Test method ISO 179/2-1eA) subsequently notched and fractured at or near
liquid nitrogen
temperatures in the longitudinal direction (parallel to the direction of
original impact fracture)
are represented in Table 6 below. Pore aspect ratios were measured on SEM
images using
ImageJ analysis software. Two automated built-in algorithms and a manual
method of setting
the threshold in ImageJ were used to obtain the average aspect ratios of
pores. Routine
background smoothing and image filtering techniques were also used. The
average pore count
for each data point in Table 6 was at least 750 or higher.
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[0151] Table 6. Porosity Aspect Ratio for -30 C Impact Test
fracture specimen of Ex.
1E.
Aspect ratio of pores at mm from notch
1 mm 4 mm 5 mm 6.5 mm
2.37 2.15 2.57 3.08
2.08 2.11 2.15 2.80
2.35 2.17 2.78 2.60
2.35 2.15 2.60 2.51
2.09 2.18 2.47 3.05
2.27 2.14 2.88
1.99 2.37
1.90 2.35
2.36 2.31
2.41 2.63
2.07 2.44
2.19 2.71
2.25 2.65
2.13 2.79
2.22
Average 2.20 2.37 2.51 2.82
Std dev 0.15 0.24 0.23 0.23
Min 1.90 2.11 2.15 2.51
Max 2.41 2.79 2.78 3.08
[0152] SEM images of longitudinal sections immediately below the
original -30 C
Charpy impact fracture surface at various lengths from the notch (shown
approximately in mm)
are displayed in FIG. 7 for Ex. 1E. The images, at magnifications of both
5000x and 10,000x,
portray a fairly consistent microstructure of extensive, elongated porosity
along the original
impact fracture length. This is an indication of cavitation and shear yielding
along the entire
fracture length of the -30 C Charpy impact tested specimens.
[0153] Porosity aspect ratio measurements made using ImageJ
analysis on the Ex. 1G,
1H, and 11 samples as shown in FIG. 11 were found to be consistent with those
shown for the
Ex. lE sample in Table 6.
[0154] FIG. 8 represents a plot and tabulated values of measured
-30 C impact strength
(kJ/m2) on the Y-axis as a function of room-temperature tensile modulus (GPa)
on the X-axis.
The tested specimen references and the DAM specimen data are given in Tables
3A and 3C. It
was observed that the Ex. 1E, 1G, 1H, and 11 specimens were differentiated
from other tested
samples of Table 2. The -30 C impact strength (kJ/m2) was more than 50%
higher than all other
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tested specimens at identical tensile modulus. The other tested specimens all
fall on a least
square regression line with an R-square value of 0.98 (shown as a line in FIG.
8).
Example 3. Room Temperature Tensile Testing
[0155] Tensile test specimens were prepared according to the ISO
527 method. Tensile
testing of the specimens was conducted at room temperature in accordance with
the ISO 527 test
method.
[0156] The fractured halves from tensile tests were used to
evaluate the internal
structures developed as a result of the tensile test. These structures offer
an understanding of the
internal mechanisms and material structural changes occurring during the
tensile test. For each
sample evaluated, the longer of the two fractured halves was selected.
Sections were notched
and fractured in the longitudinal and transverse directions at two locations:
one halfway between
the fractured surface and the grip section and the other at the start of the
neck of the grip section
as shown by the schematic in FIG. 9A. All fractures were done at or near
liquid nitrogen
temperatures to preserve the structure within the material resulting from the
tensile test.
[0157] Fracture surfaces from the two regions and two
orientations discussed above were
examined using a JSM-7200F field emission scanning electron microscope. Care
was taken that
each region evaluated was a clean fracture surface to ensure that it was
representative of the
original as-tested internal microstructure. Micrographs were recorded from the
approximate
center of each sample examined. Representative micrographs at a magnification
of 10,000x at
each of the two locations (halfway between grip and fracture surface and at
the start of the grip
section) and both orientations (transverse and longitudinal, which are
perpendicular and parallel
to the tensile axis, respectively) are shown in FIG. 9B and FIG. 12. Porosity
is clearly visible in
the micrographs for both Ex. IA and Ex. 1E at both locations. These pores are
circular in
appearance in the transverse orientations and elongated in the longitudinal
orientations (FIG.
9B). The microstructures observed are an indication that pores have formed
internally and been
stretched or elongated along the axis through the application of a tensile
force. No such porosity
was observed in the microstructures of samples that were not subjected to the
tensile test.
Further, a similar elongated pore structure was observed at several other
locations examined
along the tensile axis and on both fractured halves of the tensile specimen
for Ex. lA and Ex. 1E.
The presence of elongated pore internal microstructures throughout the tensile
specimen from
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one end of the grip to the other are indicative of cavitation (creation of
pores) and yielding
(stretching of pores) which manifests itself into the relatively high
elongation numbers observed
for these two materials in Tables 3A and 3C. In contrast, for the materials
from Ex. 2B and Ex.
2C, lower levels of porosity with almost no or very little elongation are
observed in
representative micrographs from both locations, particularly at the start of
the grip section, as
shown in FIG. 9B. Ex. 2B and Ex. 2C correspondingly exhibit relatively low
levels of percent
elongation after tensile testing as shown in Table 3A.
[0158] Image analysis using ImageJ software was used to quantify
the area fraction and
pore elongation observed in microstructures such as those shown in FIG. 9B.
The level of
porosity can be measured as % area fraction while elongation of pores is
captured by measuring
the pore aspect ratio (ratio of major to minor axis of a fitted ellipse). A
longitudinal cross-
section was selected from the start of the grip section of the tensile tested
sample for each of Ex.
1A, 1E, 2B, and 2C. Micrographs at a magnification of 5000x (representing an
area of
approximately 19x24 microns) were taken from left, center and right regions of
each sample,
with left and right regions being about 0.5 mm in from the edges. Porosity
area fractions and
aspect ratios were measured using built-in automated algorithms in the
software to set the
threshold for each image during segmentation. The average values of area
fraction and aspect
ratios measured from the three micrographs described above for each sample are
shown in Table
7. The substantial differences seen for area fractions and aspect ratios
measured through image
analysis between Ex. 1A, 1E and Ex. 2B, 2C as shown in Table 7 are in good
agreement with the
differences observed visually in the micrographs from the start of grip
section shown in FIG 9B.
They are also in good agreement with the differences in elongation (%)
observed in Table 3A,
which is a measure of ductility.
[0159] Table 7. Image analysis results from longitudinal
sections at the start of grip.
Sample Area Fraction (%) Aspect Ratio
1A 9.00 1.96
1E 7.20 2.00
2B <0.1
2C 0.20 1.45
[0160] Subsequently, multiple frames were analyzed for Ex. 1E
from longitudinal
sections located at a point halfway between the tensile fracture surface and
grip and at the start of
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the grip section at magnifications of 2000x, 5000x and 10,000x.
Microstructural SEM analysis
was done on samples taken from tensile bars tested at room temperature using
the ISO 527 test
method. As described above, notches were made in the longitudinal direction of
the specimens
and they were fractured at or near liquid nitrogen temperatures to preserve
the structure within
the material resulting from the tensile test. Two automated built-in
algorithms and a manual
method of setting the threshold in ImageJ were used to obtain porosity area
fraction and aspect
ratios from the images obtained through SEM. A summary of average values
measured are
shown in Table 8. The average pore count for each data point in Table 8 was at
least 1000 or
higher. A minimum porosity area fraction of 4% was observed for Ex. 1E.
[0161] Table 8. Porosity Aspect Ratio for Example lE specimen.
Area fraction (%) Aspect ratio
6.4 2.05
10.4 1.96
10.7 2.07
10.5 2.10
11.9 1.98
6.4 2.17
10.8 2.16
6.6 1.93
7.7 2.03
7.3 2.04
7.5 1.94
8.1 2.41
7.6 2.44
7.7 1.93
4.1 1.84
Average 8.2 2.07
Std dev 2.1 0.17
Min 4.1 1.84
Max 11.9 2.44
[0162] The Ex. lA and lE specimens showed 9.0% and 7.2% area
fractions for porosity,
respectively, while much lower (<< 1%) area fractions for porosity were
observed for the Ex. 2B
and 2C specimens. The Ex. 1A and lE specimens were observed with spherical
porosity in the
transverse section and elongated pores in the longitudinal section. In
contrast, Ex. 2B and 2C
specimens showed little to no porosity (in transverse direction) and pore
elongations (in
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longitudinal direction). The increased aspect ratio of the pores for Ex. lA
and 1E may be an
indication of a high degree of yielding implying large amounts of tensile
elongation.
[0163] Also, the porosity and elongation of pores was consistent
all the way to the start
of the grip section in Ex. 1A and 1E specimens, compared to those for Ex. 2B
and 2C.
[0164] The internal polymer microstructures of room-temperature,
ISO 527 test method
tensile test specimens of the disclosed compositions were observed to contain
>4 % porosity area
fraction and > 1.6 to < 3.0 aspect ratio (pore major axis/minor axis) for the
pores at a point
halfway between the fracture surface and the grip section and at the start of
both grip sections.
[0165] A high elongation of the tensile bar samples along with
uniform width/thickness
reduction and stress whitening along the entire elongated length was observed
for tensile bars of
Ex. 1A and 1E upon room-temperature testing. In contrast, highly localized
necking and step
fracture resulted for tensile bars of Ex. 2B and 2C upon room-temperature
testing.
[0166] Porosity measurements were similarly made using ImageJ
analysis on the Ex. 1G,
1H, and 11 samples in the longitudinal orientation as shown in FIG. 12. The
Ex. 1G, 1H, and 11
specimens exhibited porosity aspect ratios that fell within the range > 1.6 to
< 3.0 with a
minimum porosity area fraction of 4% as observed for the Ex. 1E specimen.
[0167] The terms and expressions that have been employed are
used as terms of
description and not of limitation, and there is no intention in the use of
such terms and
expressions of excluding any equivalents of the features shown and described
or portions thereof,
but it is recognized that various modifications are possible within the scope
of the aspects of the
present invention. Thus, it should be understood that although the present
invention has been
specifically disclosed by specific aspects and optional features, modification
and variation of the
concepts herein disclosed may be resorted to by those of ordinary skill in the
art, and that such
modifications and variations are considered to be within the scope of aspects
of the present
invention.
Exemplary Aspects.
[0168] The following exemplary aspects are provided, the
numbering of which is not to
be construed as designating levels of importance:
[0169] Aspect 1 provides a composition comprising a condensation
polyamide, or a
reacted product of the composition, wherein when the composition or reacted
product is formed
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into an impact test bar and tested at -30 C according to ISO 179/2-1eA to
form a -30 C notched
impact fractured surface, the composition or reacted product has:
an Sdr measurement of >10% as obtained from a surface profilometry analysis of
the -30
C notched impact fractured surface, wherein Sdr represents the degree to which
the actual
surface area increases in comparison to a flat state; or
a stress whitening zone thickness of >500 microns at a halfway distance
through the
fracture and in a transversal surface cut plane (TcuT), the transversal cut
plane being
perpendicular to the original fracture surface; or
a porosity area fraction (%) within the first 50 microns below the -30 C
notched impact
fractured surface in a transverse cross-section direction taken at >3 to <5 mm
linear distance
from the notch of >5% to <31%, or
a porosity area fraction (%) at a depth of about 100 microns below the -30 C
notched
impact fractured surface in a transverse cross-section direction taken at >3
to <5 mm linear
distance from the notch of >2% to <17%; or
a numerical mean of the aspect ratio (pore major axis/minor axis) of a
representative
sample of pores measured within the first 50 microns below the -30 C notched
impact fractured
surface and along a longitudinal cross-section taken at >3 to <5 mm linear
distance from the
notch of >1.8 to <3.1 and a porosity area fraction measured in the same
location as the numerical
mean of the aspect ratio of at least 5%, or
a combination thereof.
[0170] Aspect 2 provides the composition or reacted product of
Aspect 1, wherein the Sdr
is 10% to 30%.
[0171] Aspect 3 provides the composition or reacted product of
any one of Aspects 1-2,
wherein the Sdr is 10% to 15%.
[0172] Aspect 4 provides the composition or reacted product of
any one of Aspects 1-3,
wherein the stress whitening zone thickness is 500 microns to 800 microns at a
halfway distance
through the fracture and in the TCLT plane.
[0173] Aspect 5 provides the composition or reacted product of
any one of Aspects 1-4,
wherein the stress whitening zone thickness is 550 microns to 700 microns at a
halfway distance
through the fracture and in the TCUT plane.
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[0174] Aspect 6 provides the composition or reacted product of
any one of Aspects 1-5,
wherein the porosity area fraction (%) is > 8% to < 27%.
[0175] Aspect 7 provides the composition or reacted product of
any one of Aspects 1-6,
wherein the porosity area fraction (%) is > 12% to < 23%.
[0176] Aspect 8 provides the composition or reacted product of
any one of Aspects 1-7,
wherein the numerical mean of the aspect ratio is >1.8 to <3.1 and a porosity
area fraction
measured in the same location as the numerical mean of the aspect ratio is at
least 5%.
[0177] Aspect 9 provides the composition or reacted product of
any one of Aspects 1-8,
wherein the numerical mean of the aspect ratio is >2.0 to <3Ø
[0178] Aspect 10 provides the composition or reacted product of
any one of Aspects 1-9,
wherein the numerical mean of the aspect ratio is >2.1 to <2.8.
[0179] Aspect I I provides the composition or reacted product of
any one of Aspects I -
10, wherein a porosity area fraction (%) at a depth of about 100 microns below
the -30 C
notched impact fractured surface in a transverse cross-section direction taken
at >3 to <5 mm
linear distance from the notch is >2% to <17%.
[0180] Aspect 12 provides the composition or reacted product of
any one of Aspects 1-
11, wherein a porosity area fraction (%) at a depth of about 100 microns below
the -30 C
notched impact fractured surface in a transverse cross-section direction taken
at >3 to <5 mm
linear distance from the notch is >3% to <14%.
[0181] Aspect 13 provides the composition or reacted product of
any one of Aspects 1-
12, wherein a porosity area fraction (%) at a depth of about 100 microns below
the -30 C
notched impact fractured surface in a transverse cross-section direction taken
at >3 to <5 mm
linear distance from the notch is >4% to <12%.
[0182] Aspect 14 provides a composition comprising a
condensation polyamide, or a
reacted product of the composition, wherein when the composition or reacted
product is formed
into an impact test bar and tested at -30 C according to ISO 179/2-1eA to
form a -30 C notched
impact fractured surface, the composition or reacted product has.
a porosity area fraction (%) measured within the first 50 microns below the -
30 C
notched impact fractured surface in a transverse cross-section direction taken
at >3 to <5 mm
linear distance from the notch of >5% to <31%, and
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a porosity area fraction (%) measured at a depth of about 100 microns below
the -30 C
notched impact fractured surface in a transverse cross-section direction taken
at >3 to <5 mm
linear distance from the notch of >2% to <17%.
[0183] Aspect 15 provides a composition or reacted product of
Aspect 14, wherein when
the composition or reacted product thereof is formed into a tensile test bar
according to ISO 527
and fractured at room temperature in accordance with ISO 527, it exhibits an
internal
microstructure having >4% porosity area fraction and an aspect ratio (pore
major axis/minor
axis) at a halfway point between the fracture surface and the grip sections
and at the start of the
grip sections of >1.6 to <3Ø
[0184] Aspect 16 provides a composition comprising a
condensation polyamide, or a
reacted product of the composition, wherein when the composition or reacted
product thereof is
formed into a tensile test bar according to ISO 527 and fractured at room
temperature in
accordance with ISO 527, it exhibits an internal microstructure having >4%
porosity area
fraction and an aspect ratio (pore major axis/minor axis) at a halfway point
between the fracture
surface and the grip sections and at the start of the grip sections of > 1.6
to < 3Ø
[0185] Aspect 17 provides the composition or reacted product of
Aspect 16, wherein the
porosity area fraction is greater than or equal to 5%.
[0186] Aspect 18 provides the composition or reacted product of
any one of Aspects 16-
17, wherein the porosity area fraction is >5% to <31%.
[0187] Aspect 19 provides the composition or reacted product of
any one of Aspects 16-
18, wherein the aspect ratio is >1.7 to <2.8.
[0188] Aspect 20 provides the composition or reacted product of
any one of Aspects 16-
19, wherein the aspect ratio is >1.8 to <2.5.
[0189] Aspect 21 provides a composition comprising a
condensation polyamide and a
maleated polyolefin, or a reacted product of the composition, the condensation
polyamide
comprising nylon 66, wherein the amine end group (AEG) index of the nylon 66
is >65 and
<130, wherein an unpolished microtome-cut pellet formed from the composition
or reacted
product thereof subjected to toluene etching at 90 C for 2 hours has a
surface that, as compared
using a magnification of 3000x to 5000x (e.g., using a scanning electron
microscope), is less
pitted than an identical composition or reacted product thereof (e.g.,
comparative composition or
reacted product thereof) that is free of the maleated polyolefin and/or
wherein the nylon 66 of the
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comparative composition or reacted product thereof has an amine end group
(AEG) index of
<65.
[0190]
Aspect 22 provides the composition or reacted product of any one of Aspects
1-
21, wherein when the composition or reacted product is formed into an impact
test bar and tested
at -30 C according to ISO 179/2-leA to form a -30 C notched impact fractured
surface, the
composition or reacted product has an Scii measurement of >10% as obtained
from a surface
profilometry analysis of the -30 C notched impact fractured surface, wherein
Sar represents the
degree to which the actual surface area increases in comparison to a flat
state, wherein a -30 C
impact strength (kJ/m2) of the composition or reacted product is at least 40%
higher at an
identical tensile modulus (GPa) as compared to a composition including a
condensation
polyamide or reaction product thereof that does not have an Sdr measurement of
>10% as
obtained from a surface profilometry analysis of a -30 C notched impact
fractured surface
thereof.
[0191]
Aspect 23 provides the composition or reacted product of any one of Aspects
1-
22, wherein when the composition or reacted product is formed into an impact
test bar and tested
at -30 'V according to ISO 179/2-1eA to form a -30 C notched impact fractured
surface, the
composition or reacted product has a stress whitening zone thickness of >500
microns at a
halfway distance through the fracture and in a transversal surface cut plane
(TcuT), the
transversal cut plane being perpendicular to the original fracture surface.
[0192]
Aspect 24 provides the composition or reacted product of any one of Aspects
1-
23, wherein when the composition or reacted product is formed into an impact
test bar and tested
at -30 C according to ISO 179/2-1eA to form a -30 C notched impact fractured
surface, the
composition or reacted product has a porosity area fraction (%) measured
within the first 50
microns below the -30 C notched impact fractured surface in a transverse
cross-section direction
taken at >3 to <5 mm linear distance from the notch of >5% to <31%.
[0193]
Aspect 25 provides the composition or reacted product of any one of Aspects
1-
24, wherein when the composition or reacted product is formed into an impact
test bar and tested
at -30 'V according to ISO 179/2-leA to form a -30 'V notched impact fractured
surface, the
composition or reacted product has a numerical mean of the aspect ratio (pore
major axis/minor
axis) of a representative sample of pores measured within the first 50 microns
below the -30 C
notched impact fractured surface and along a longitudinal cross-section taken
at >3 to <5 mm
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linear distance from the notch of >1.8 to <3.1 and a porosity area fraction
measured in the same
location as the numerical mean of the aspect ratio of at least 5%.
[0194] Aspect 26 provides the composition or reacted product of
any one of Aspects 1-
25, wherein the composition comprises:
the condensation polyamide, wherein the condensation polyamide is at least 30
wt% of
the composition, wherein the condensation polyamide is the predominant
polyamide in the
composition; and
from >10 wt% to <50 wt% of maleated polyolefin (e.g., >10 wt% to <50 wt%, such
as
>15 wt% to <50 wt%, >15 wt% to <45 wt%, >20 wt% to <50 wt%, >20 wt% to <45
wt%, or less
than or equal to 50 wt% but greater than or equal to 10 wt%, 11, 12, 13, 14,
15, 16, 17, 18, 19,
20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 41, 42, 43, 44, 45, 46,
47, 48, or 49%), wherein
the maleated polyolefin comprises maleic anhydride grafted onto a polyolefin
backbone, the
maleated polyolefin having a grafted maleic anhydride incorporation of >0.05
to <1.5 wt% based
on total weight of the maleated polyolefin.
[0195] Aspect 27 provides the composition or reacted product of
Aspect 26, wherein the
condensation polyamide is 30-99.9 wt% of the composition.
[0196] Aspect 28 provides the composition or reacted product of
any one of Aspects 26-
27, wherein the condensation polyamide is 60-99.9 wt% of the composition.
[0197] Aspect 29 provides the composition or reacted product of
any one of Aspects 26-
28, wherein the condensation polyamide is >40 to <50 wt% of the composition.
[0198] Aspect 30 provides the composition or reacted product of
any one of Aspects 26-
29, wherein the condensation polyamide is chosen from nylon 66, nylon 66/6T,
nylon 66/61,
nylon 66/DI, and a combination thereof
[0199] Aspect 31 provides the composition or reacted product of
any one of Aspects 26-
30, wherein the condensation polyamide is nylon 66 having an AEG of >65
milliequivalents per
kg (meq/kg) and <130 meq/kg.
[0200] Aspect 32 provides the composition or reacted product of
any one of Aspects 26-
31, wherein the condensation polyamide is a nylon 66/MPMD-I copolymer.
[0201] Aspect 33 provides the composition or reacted product of
any one of Aspects 26-
32, wherein the condensation polyamide is chosen from nylon 66, nylon 66/6T,
nylon 66/61, and
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a combination thereof, and wherein the composition further comprises a nylon-
6,6/MPMD-I
copolymer.
[0202] Aspect 34 provides the composition or reacted product of
Aspect 33, wherein the
condensation polyamide is nylon 66.
[0203] Aspect 35 provides the composition or reacted product of
any one of Aspects 26-
34, wherein the condensation polyamide is 30 wt% to 60 wt% of the polyamide
composition.
[0204] Aspect 36 provides the composition or reacted product of
any one of Aspects 33-
35, wherein the nylon 66/1VIPMD-I copolymer is a random copolymer.
[0205] Aspect 37 provides the composition or reacted product of
any one of Aspects 33-
36, wherein the nylon 66/MPMD-I copolymer is >2 to <50 wt% of the composition.
[0206] Aspect 38 provides the composition or reacted product of
any one of Aspects 33-
37, wherein the nylon 66/MPMD-I copolymer is >25 to <35 wt% of the
composition.
[0207] Aspect 39 provides the composition or reacted product of
any one of Aspects 26-
38, wherein the composition or reacted product thereof has a recycled amine
content of >0.2
wt% to < 10 wt%.
[0208] Aspect 40 provides the composition or reacted product of
any one of Aspects 26-
39, wherein the composition further comprises an additional polyamide
comprising nylon 66,
nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/61, nylon
66/DI, nylon 66/D6,
nylon 66/DT, nylon 66/610, nylon 66/612, nylon 11, nylon 46, nylon 69, nylon
1010, nylon
1212, nylon 6T/DT, nylon DT/DI, a polyamide copolymer, or a combination
thereof, wherein the
additional polyamide is >0 to <85 wt% of the composition.
[0209] Aspect 41 provides the composition or reacted product of
Aspect 40, wherein the
additional polyamide is >15 to <85 wt% of the composition.
[0210] Aspect 42 provides the composition or reacted product of
any one of Aspects 40-
41, wherein the additional polyamide is nylon 6.
[0211] Aspect 43 provides the composition or reacted product of
Aspect 42, wherein the
nylon 6 is >0 to <1 wt% of the composition.
[0212] Aspect 44 provides the composition or reacted product of
any one of Aspects 26-
43, wherein the composition is free of nylon 6.
[0213] Aspect 45 provides the composition or reacted product of
any one of Aspects 26-
44, wherein the composition is free of reinforcing fibers.
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[0214] Aspect 46 provides the composition or reacted product of
any one of Aspects 26-
45, wherein the composition comprises 0 wt% to 2 wt% reinforcing fibers.
[0215] Aspect 47 provides the composition or reacted product of
any one of Aspects 26-
46, wherein the composition comprises glass fibers.
[0216] Aspect 48 provides the composition or reacted product of
Aspect 47, wherein the
glass fibers are >1 wt% to <50 wt% of the composition.
[0217] Aspect 49 provides the composition or reacted product of
any one of Aspects 47-
48, wherein the glass fibers are >10 wt% to <42 wt% of the composition.
[0218] Aspect 50 provides the composition or reacted product of
any one of Aspects 47-
49, wherein the glass fibers are >10 wt% to <35 wt% of the composition.
[0219] Aspect 51 provides the composition or reacted product of
any one of Aspects 47-
50, wherein the glass fibers are ?I 5 wt% to <30 wt% of the composition.
[0220] Aspect 52 provides the composition or reacted product of
any one of Aspects 26-
51, wherein the maleated polyolefin comprises a polyolefin backbone that
comprises EPDM,
ethylene-octene, polyethylene, polypropylene, or a combination thereof.
[0221] Aspect 53 provides the composition or reacted product of
any one of Aspects 26-
52, wherein the maleated polyolefin is free of EPDM.
[0222] Aspect 54 provides the composition or reacted product of
any one of Aspects 26-
53, wherein the maleated polyolefin has a grafted maleic anhydride
incorporation of >0.1 to <1.4
wt% based on total weight of the maleated polyolefin.
[0223] Aspect 55 provides the composition or reacted product of
any one of Aspects 26-
54, wherein the maleated polyolefin has a grafted maleic anhydride
incorporation of >0.15 to
<1.25 wt% based on total weight of the maleated polyolefin.
[0224] Aspect 56 provides the composition or reacted product of
any one of Aspects 26-
55, wherein the maleated polyolefin has a glass transition temperature (Tg) of-
70 C to <0 C.
[0225] Aspect 57 provides the composition or reacted product of
any one of Aspects 26-
56, wherein the maleated polyolefin has a glass transition temperature (Tg) of-
60 C to <-20 C.
[0226] Aspect 58 provides the composition or reacted product of
any one of Aspects 26-
57, wherein the maleated polyolefin has a glass transition temperature (Tg) of-
60 C to <-30 C.
[0227] Aspect 59 provides the composition or reacted product of
any one of Aspects 26-
58, wherein
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the condensation polyamide has an AEG of >65 millieguivalents per kg (meg/kg)
and
<130 meg/kg, or
the maleated polyolefin, or domains thereof, is/are uniformly distributed in
the
condensation polyamide or in the composition, or
the condensation polyamide has an RV of at least 35, or
the condensation polyamide is chosen from nylon 66, nylon 66/6T, nylon 66/61,
nylon
66/DI, and a combination thereof, or
a combination thereof
[0228] Aspect 60 provides the composition or reacted product of
any one of Aspects 26-
59, wherein the composition is a compounded composition comprising one or more
other
components.
[0229] Aspect 61 provides the composition or reacted product of
Aspect 60, wherein the
one or more other components comprise a modified polyphenylene ether, an
impact modifier, a
flame retardant, a chain extender, a heat stabilizer, a colorant additive, a
filler, a conductive fiber,
glass fibers, another polyamide other than the condensation polyamide, or a
combination thereof
[0230] Aspect 62 provides the composition or reacted product of
any one of Aspects 60-
61, wherein the one or more other components comprise a chain extender
comprising a
dialcohol, a bis-epoxide, a polymer comprising epoxide functional groups, a
polymer comprising
anhydride functional groups, a bis-N-acylbis-caprolactam, a diplienyl
carbonate, a bisoxazoline,
an oxazolinone, a diisocyanate, an organic phosphite, a bis-ketenimine, a
dianhydride, a
carbodiimide, a polymer comprising carbodiimide functionality, or a
combination thereof
[0231] Aspect 63 provides the composition or reacted product of
any one of Aspects 60-
62, wherein the one or more other components comprise a chain extender,
wherein the chain
extender is >0.05 to <5 wt% of the compounded polyamide composition.
[0232] Aspect 64 provides the composition or reacted product of
Aspect 63, wherein the
chain extender comprises a maleic anhydride-polyolefin copolymer
[0233] Aspect 65 provides the composition or reacted product of
any one of Aspects 1-
64, wherein the composition exhibits melt strength of >0.3 to <1.0 N in a
Rheotens test
conducted at 270 C to 290 C, a moisture level of 0.03-0.1%, and an extrusion
speed of 300-700
mm/s.
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[0234] Aspect 66 provides the composition or reacted product of
Aspect 65, wherein the
melt strength is >0.8 N to <1.0 N.
[0235] Aspect 67 provides the composition or reacted product of
any one of Aspects 1-
66, wherein the maleated polyolefin primarily resides in islands in a
condensation polyamide sea.
[0236] Aspect 68 provides the reacted product of any one of
Aspects 26-67, wherein the
reacted product is a reaction product of the composition of any one of Aspects
26-67, wherein
the reacted product comprises a polyamide-polyolefin copolymer formed from at
least partial
reaction of the condensation polyamide and the maleated polyolefin of the
composition of any
one of Aspects 26-67.
[0237] Aspect 69 provides the reacted product of Aspect 68,
wherein the reacted product
comprises the polyamide-polyolefin copolymer in a concentration range of >50
to <7500 ppmw,
based on the total weight of the reacted product.
[0238] Aspect 70 provides the reacted product of any one of
Aspects 68-69, wherein the
reacted product comprises the polyamide-polyolefin copolymer in a
concentration range of >100
to <4900 ppmw, based on the total weight of the reacted product.
[0239] Aspect 71 provides the reacted product of any one of
Aspects 68-70, wherein the
reacted product comprises the polyamide-polyolefin copolymer in a
concentration range of >225
to <3750 ppmw, based on the total weight of the reacted product.
[0240] Aspect 72 provides the reacted product of any one of
Aspects 26-71, wherein the
reacted product exhibits melt strength of >0.3 to <1.0 N in a Rheotens test
conducted at 270 C to
290 C, a moisture level of 0.03-0.1%, and an extrusion speed of 300-700 mm/s.
[0241] Aspect 73 provides the reacted product of Aspect 72,
wherein the melt strength is
>0.8 to <1.0 N.
[0242] Aspect 74 provides the composition or reacted product of
any one of Aspects 26-
73, the composition comprising:
the condensation polyamide, wherein the condensation polyamide is at least 40
wt% of
the composition, wherein the condensation polyamide is the predominant
polyamide in the
composition, wherein the condensation polyamide is nylon 66 having an AEG of
>65
millieguivalents per kg (meg/kg) and <130 meg/kg; and
from >15 wt% to <45 wt% of maleated polyolefin, wherein the maleated
polyolefin
comprises maleic anhydride grafted onto a polyolefin backbone, the maleated
polyolefin having
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a grafted maleic anhydride incorporation of >0.05 to <1.5 wt% based on total
weight of the
maleated polyolefin.
[0243] Aspect 75 provides an article formed from the composition
or reacted product of
any one of Aspects 1-74 or a combination thereof.
[0244] Aspect 76 provides the article of Aspect 75, wherein the
article is resistant to
cold-temperature cracking.
[0245] Aspect 77 provides the article of any one of Aspects 75-
76, wherein the article is
a molded article.
[0246] Aspect 78 provides the article of any one of Aspects 75-
77, wherein the article is
an extrudate.
[0247] Aspect 79 provides the article of any one of Aspects 75-
78, wherein the article is
a conduit.
[0248] Aspect 80 provides the article of Aspect 79, wherein the
conduit is chosen from
rigid, flexible, curved, bent, serpentine, partially corrugated, fully
corrugated, and a combination
thereof
[0249] Aspect 81 provides the article of any one of Aspects 79-
80, wherein the conduit
has a cross-section chosen from round, oval, oblong, square, rectangle,
triangle, star, polygonal,
and a combination thereof.
[0250] Aspect 82 provides the article of any one of Aspects 75-
81, wherein the article is
substantially free of glass fibers.
[0251] Aspect 83 provides the article of any one of Aspects 75-
82, wherein the article is
an extruded conduit.
[0252] Aspect 84 provides the article of any one of Aspects 75-
83, wherein the article is
an extruded sheet.
[0253] Aspect 85 provides the article of Aspect 84, wherein the
article is a folded
extruded sheet.
[0254] Aspect 86 provides the article of any one of Aspects 84-
85, wherein the sheet is a
film.
[0255] Aspect 87 provides the article of any one of Aspects 84-
86, wherein the sheet has
a thickness of 0.01 mm to 10 mm.
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[0256] Aspect 88 provides the article of any one of Aspects 86-
87, wherein the sheet has
a thickness of 0.2 mm to 6 mm.
[0257] Aspect 89 provides the article of any one of Aspects 86-
88, wherein a width-to-
thickness ratio of the sheet is at least 10.
[0258] Aspect 90 provides the article of any one of Aspects 86-
89, wherein a width-to-
thickness ratio of the sheet is >10 to <40,000.
[0259] Aspect 91 provides the article of any one of Aspects 86-
90, wherein the sheet
exhibits an impact resistance in k.l7m2 that is within 10% of an impact
resistance of a
polycarbonate sheet of like thickness under like impact resistance testing
conditions.
[0260] Aspect 92 provides the article of any one of Aspects 75-
91, wherein the article
comprises a film, a mat, a liner, a flooring, a construction material, a pad,
a shutter, a panel, a
belt, a slide, an enclosure, a vehicle component, an architectural component,
or a combination
thereof.
[0261] Aspect 93 provides the article of any one of Aspects 75-
92, wherein the article
comprises a slip sheet, a die cutting mat, a silo liner, a die cutting mat, a
truck bed liner, flooring,
a construction material, a ground pad, a construction envelope system, a storm-
resistant shutter, a
hail-resistant panel, a geo-textile, a conveying system component, an
electronic equipment
enclosure, or a combination thereof.
[0262] Aspect 94 provides a method of making the composition or
reacted product of any
one of Aspects 26-74 or a combination thereof, the method comprising:
combining the condensation polyamide and the maleated polyolefin to form the
composition or reacted product of any one of Aspects 26-74 or a combination
thereof.
[0263] Aspect 95 provides the method of Aspect 94, wherein the
method comprises
combining the condensation polyamide and the maleated polyolefin before adding
a chain
extender thereto.
[0264] Aspect 96 provides the method of Aspect 95, comprising:
providing to a first compounder extruder zone a feed comprising the
condensation
polyamide and the maleated polyolefin;
maintaining the first compounder extruder zone conditions sufficient to obtain
a first
compounded polyamide melt inside the first compounder extruder zone;
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introducing a chain extender to the first compounded polyamide melt in a
second
compounder extruder zone; and
maintaining the second compounder extruder zone conditions sufficient to
obtain a
second compounded polyamide melt inside the second compounder extruder zone,
wherein the
second compounded polyamide melt is the composition or reacted product of any
one of Aspects
26-74 or a combination thereof.
[0265] Aspect 97 provides the method of Aspect 96, wherein
a barrel of a screw extruder comprises the first compounder extruder zone and
the second
compounder extruder zone;
the providing of the feed to the first compounder extrusion zone comprises
providing the
feed to a feed inlet of the barrel,
the barrel has a length; and
the chain extender is introduced to the second compounder extruder zone at
least 1/4 of
the length of the barrel from the feed inlet of the barrel.
[0266] Aspect 98 provides the method of any one of Aspects 96-
97, wherein the
introducing of the chain extender to the first compounded polyamide melt in
the second
compounder extruder zone comprises introducing the chain extender to the first
compounded
polyamide melt after at least 50 wt% of the maleated polyolefin fed has
incorporated into the
condensation polyamide.
[0267] Aspect 99 provides a method of extrusion of a polyamide
resin, the method
comprising:
providing the composition or reacted product of any one of Aspects 26-74 or a
combination thereof to a feed zone of an extruder;
maintaining extruder barrel conditions sufficiently to obtain a polyamide
resin melt inside
the extruder; and
producing extrudate from the extruder while optionally recovering vapor from
the
extruder via a vacuum draw.
[0268] Aspect 100 provides a composition comprising a
condensation polyamide, or a
reacted product of the composition, wherein:
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when the composition or reacted product is formed into an impact test bar and
tested at -
30 C according to ISO 179/2-leA to form a -30 C notched impact fractured
surface, the
composition or reacted product has:
an Scr measurement of >10% as obtained from a surface profilometry analysis of
the -30 C notched impact fractured surface, wherein Sch- represents the
degree to which the
actual surface area increases in comparison to a flat state, or
a stress whitening zone thickness of >500 microns at a halfway distance
through
the fracture and in a transversal surface cut plane (Tcur), the transversal
cut plane being
perpendicular to the original fracture surface, or
a porosity area fraction (%) within the first 50 microns below the -30 C
notched
impact fractured surface in a transverse cross-section direction taken at >3
to <5 nun linear
distance from the notch of >5% to <3 I %, or
a porosity area fraction (%) within the first 50 microns below the -30 C
notched
impact fractured surface in a transverse cross-section direction taken at >3
to <5 mm linear
distance from the notch of >5% to <31% and a porosity area fraction (%) at a
depth of about 100
microns below the -30 C notched impact fractured surface in a transverse
cross-section direction
taken at >3 to <5 mm linear distance from the notch of >2% to <17%, or
a numerical mean of the aspect ratio (pore major axis/minor axis) of a
representative sample of pores measured within the first 50 microns below the -
30 C notched
impact fractured surface and along a longitudinal cross-section taken at >3 to
15 mm linear
distance from the notch of >1.8 to <3.1 and a porosity area fraction measured
in the same
location as the numerical mean of the aspect ratio of at least 5%, or
a combination thereof or
when the composition or reacted product thereof is formed into a tensile test
bar
according to ISO 527 and fractured at room temperature in accordance with ISO
527, it exhibits
an internal microstructure having >4% porosity area fraction and an aspect
ratio (pore major
axis/minor axis) at a halfway point between the fracture surface and the grip
sections and at the
start of the grip sections of? 1.6 to < 3.0; or
a combination thereof
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[0269]
Aspect 101 provides the composition, reacted product, article, or method of
any
one or any combination of Aspect 1-100 optionally configured such that all
elements or options
recited are available to use or select from.
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